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WO2025176991A1 - Système de distribution d'aérosol - Google Patents

Système de distribution d'aérosol

Info

Publication number
WO2025176991A1
WO2025176991A1 PCT/GB2025/050329 GB2025050329W WO2025176991A1 WO 2025176991 A1 WO2025176991 A1 WO 2025176991A1 GB 2025050329 W GB2025050329 W GB 2025050329W WO 2025176991 A1 WO2025176991 A1 WO 2025176991A1
Authority
WO
WIPO (PCT)
Prior art keywords
susceptor
cartridge
aerosol
examples
liquid
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/GB2025/050329
Other languages
English (en)
Inventor
James Sheridan
Lewis CONNER
Steven Ly
Daniel Law
Scott George BOHAM
Richard HAINES
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nicoventures Trading Ltd
Original Assignee
Nicoventures Trading Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Nicoventures Trading Ltd filed Critical Nicoventures Trading Ltd
Publication of WO2025176991A1 publication Critical patent/WO2025176991A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/46—Shape or structure of electric heating means
    • A24F40/465—Shape or structure of electric heating means specially adapted for induction heating
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts
    • A24F40/42—Cartridges or containers for inhalable precursors
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/10—Devices using liquid inhalable precursors
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24F—SMOKERS' REQUISITES; MATCH BOXES; SIMULATED SMOKING DEVICES
    • A24F40/00—Electrically operated smoking devices; Component parts thereof; Manufacture thereof; Maintenance or testing thereof; Charging means specially adapted therefor
    • A24F40/40—Constructional details, e.g. connection of cartridges and battery parts

Definitions

  • the cartomiser generally includes a reservoir of liquid and an atomiser for vaporising the liquid. These parts may collectively be designated as an aerosol source.
  • the atomiser generally combines the functions of porosity or wicking and heating in order to transport liquid from the reservoir to a location where it is heated and vaporised.
  • the control unit generally includes a battery for supplying power to operate the system. Electrical power from the battery is delivered to activate the heater, which heats up to vaporise a small amount of liquid delivered from the reservoir. The vaporised liquid is then inhaled by the user.
  • the components of the cartomiser can be intended for short term use only, so that the cartomiser is a disposable component of the system, also referred to as a consumable.
  • the control unit is typically intended for multiple uses with a series of cartomisers, which the user replaces as each expires.
  • Consumable cartomisers are supplied to the consumer with a reservoir pre-filled with liquid, and intended to be disposed of when the reservoir is empty.
  • the reservoir is sealed and designed not to be easily refilled, since the liquid may be difficult to handle. It is simpler for the user to replace the entire cartomiser when a new supply of liquid is needed.
  • cartomisers are straightforward to manufacture and comprise few parts, whilst providing a suitable amount of vapour upon activation of the heater. They can hence be efficiently manufactured in large quantities at low cost with minimum waste without comprising the user’s vaping experience. Cartomisers of a simple design which allow for efficient heating are hence of interest.
  • a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate comprises an insertion portion defining at least in part an aerosol chamber and a substrate region, the insertion portion defined by a longitudinal axis corresponding to an insertion direction; and the cartridge comprises a susceptor provided within the insertion portion, the susceptor comprising a planar surface separating the aerosol chamber from the substrate region, wherein the planar surface is provided parallel to the longitudinal axis.
  • the planar surface extends through a centre of a cross-section of the insertion portion which is perpendicular to the longitudinal axis.
  • the cross-section of the insertion proportion comprises an elliptical or circular periphery, wherein the planar surface is coparallel with a diameter of the cross-section.
  • the planar surface is defined by a length and a width, wherein the length is greater than the width, and wherein the length is parallel to the longitudinal axis, wherein the length is in the range of 5 mm to 50 mm and wherein the width is in the range of 2 mm to 15 mm.
  • the susceptor comprises a plurality of apertures extending through the susceptor.
  • the susceptor is formed of a material having a capillary structure configured to wick a liquid aerosol generating substrate.
  • the susceptor comprises a planar element, the planar element having a thickness in the range of one or more of 20 pm to 70 pm, 30 pm to 60 pm, and 40 pm to 55 pm.
  • the cartridge comprises a reservoir for a liquid aerosol generating substrate, wherein the cartridge is configured to supply liquid aerosol generating substrate from the reservoir to the susceptor.
  • the substrate region comprises a liquid transport element configured to wick the liquid aerosol generating substrate towards the susceptor.
  • the liquid transport element is formed of a susceptor material.
  • the substrate region comprises one or more liquid flow channels for guiding liquid aerosol generating substrate from the reservoir.
  • the insertion portion comprises a plurality of ribs, each of which is configured to abut a respective portion of the liquid transport element, wherein the one or more liquid flow channels are defined between respective pairs of ribs of the plurality of ribs.
  • the cartridge comprises a sub-reservoir provided at or towards an opposite end of the susceptor to the reservoir, the sub-reservoir configured to hold a smaller volume of liquid aerosol generating substrate than the reservoir, and wherein the cartridge is configured to supply liquid from the sub-reservoir to the susceptor.
  • a mouthpiece for use with a cartridge in accordance with the first aspect.
  • the mouthpiece comprises an outlet and a cavity configured to accommodate at least a portion of the cartridge.
  • the mouthpiece comprises an opening mechanism configured to allow the mouthpiece to be moved between a first configuration and a second configuration, wherein in the first configuration the cavity is at least partially exposed in order to allow a cartridge to be inserted and I or removed, and wherein the second configuration is configured to retain a cartridge provided within the cavity.
  • an induction assembly for use with a cartridge in accordance with the first aspect.
  • the induction assembly comprising an induction element disposed about a longitudinal axis corresponding to an insertion direction of an insertion portion of the cartridge; wherein the induction element is operable to induce current flow in the susceptor to inductively heat the susceptor to aerosolise a portion of the aerosol generating substrate in the vicinity of the susceptor.
  • an aerosol delivery system for generating an aerosol from an aerosol generating substrate.
  • the aerosol delivery system comprising a cartridge in accordance with the first aspect, and an induction assembly in accordance with the third aspect.
  • the aerosol delivery system comprises a mouthpiece in accordance with the second aspect.
  • the aerosol delivery system comprises a device part comprising control circuitry for controlling the supply of power to the induction element, wherein the control circuitry is configured to drive the induction element of the induction assembly to induce current flow in the susceptor to inductively heat the susceptor and so vaporise a portion of the aerosol generating substrate in the vicinity of the susceptor.
  • Figure 1 shows a schematic diagram of an example aerosol/vapour delivery system in accordance with aspects of the present disclosure
  • Figure 3 shows an exploded perspective view of an example cartridge in accordance with aspects of the present disclosure
  • Figure 4A shows a schematic cross-sectional view parallel to a longitudinal axis of an example cartridge in accordance with aspects of the present disclosure
  • Figure 6 shows a flow diagram depicting a method of generating an aerosol from an aerosol generating substrate in an aerosol delivery system in accordance with the present disclosure.
  • a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate comprising an insertion portion defining at least in part an aerosol chamber and a substrate region, the insertion portion defined by a longitudinal axis corresponding to an insertion direction; and a susceptor provided within the insertion portion, the susceptor comprising a planar surface separating the aerosol chamber from the substrate region, wherein the planar surface is provided parallel to the longitudinal axis.
  • a cartridge as described above comprises a susceptor which can be efficiently heated due to the positioning of the susceptor relative to insertion direction, hence improving the position of the susceptor in an induction element when the insertion portion is inserted into an induction assembly.
  • the cartridge is relatively simple to manufacture because of the side by side arrangement of the aerosol chamber and substrate region which is created by positioning the planar surface to separate the aerosol chamber and substrate region.
  • delivery system is intended to encompass systems that deliver at least one substance to a user, and includes non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosolgenerating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and
  • a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
  • the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
  • the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
  • END electronic nicotine delivery system
  • the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
  • the non-combustible aerosol provision system such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller.
  • the power source may, for example, be an electric power source.
  • the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
  • the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
  • the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised.
  • either material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.
  • the active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response.
  • the active substance may for example be selected from nutraceuticals, nootropics, psychoactives.
  • the active substance may be naturally occurring or synthetically obtained.
  • the active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof.
  • the active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.
  • the active substance is a legally permissible recreational drug.
  • the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.
  • the active substance may be CBD or a derivative thereof.
  • the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof.
  • botanical includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like.
  • the material may comprise an active compound naturally existing in a botanical, obtained synthetically.
  • the material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like.
  • Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon
  • the mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens
  • the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.
  • the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.
  • the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel.
  • the substance to be delivered comprises a flavour.
  • flavour and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch,
  • the flavour comprises menthol, spearmint and/or peppermint.
  • the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry.
  • the flavour comprises eugenol.
  • the flavour comprises flavour components extracted from tobacco.
  • the flavour comprises flavour components extracted from cannabis.
  • the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect.
  • a suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.
  • Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. In some embodiments, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
  • the aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.
  • the aerosol-former material may comprise one or more constituents capable of forming an aerosol.
  • the aerosol-former material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1 ,3- butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.
  • the one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
  • a consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user.
  • a consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosolgenerating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent.
  • a consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use.
  • the heater may comprise a susceptor.
  • a susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field.
  • the susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material.
  • the heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material.
  • the susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms.
  • the device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.
  • An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol.
  • the aerosol-modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent
  • the aerosol-modifying agent may, for example, be an additive or a sorbent.
  • the aerosolmodifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent.
  • the aerosol-modifying agent may, for example, be a solid, a liquid, or a gel.
  • the aerosol-modifying agent may be in powder, thread or granule form.
  • the aerosolmodifying agent may be free from filtration material.
  • An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material.
  • the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.
  • FIG. 1 is a highly schematic diagram (not to scale) of an example aerosol/vapour delivery system 10 in accordance with the present disclosure.
  • the system 10 has a generally elongate shape in this example, extending along a longitudinal axis, and comprises two main components, namely a control or power component, section or unit 20 (sometimes also referred to as an aerosol/vapour delivery device), and a cartridge assembly or section 30 (sometimes referred to as a cartomiser or clearomiser) carrying aerosolisable substrate material and operating as a vapour-generating component.
  • a control or power component section or unit 20
  • a cartridge assembly or section 30 sometimes referred to as a cartomiser or clearomiser
  • the cartridge 30 includes a reservoir 33 containing a source liquid (sometimes called a liquid aerosol generating material) or other aerosolisable substrate material comprising a formulation such as liquid or gel from which an aerosol is to be generated, for example containing nicotine.
  • a source liquid sometimes called a liquid aerosol generating material
  • the source liquid may comprise around 1 to 3% nicotine and 50% glycerol, with the remainder comprising roughly equal measures of water and propylene glycol, and possibly also comprising other components, such as flavourings. Nicotine-free source liquid may also be used, such as to deliver flavouring.
  • a solid substrate (not illustrated), such as a portion of tobacco or other flavour element through which vapour generated from the liquid is passed, may also be included.
  • the reservoir 33 has the form of a storage tank, being a container or receptacle in which source liquid can be stored such that the liquid is free to move and flow within the confines of the tank.
  • the reservoir 33 may be sealed after filling during manufacture so as to be disposable after the source liquid is consumed, otherwise, it may have an inlet port or other opening through which new source liquid can be added by the user.
  • the cartridge 30 also comprises a susceptor 34 (sometimes called a heater, a susceptor heater or a susceptor heating element) for generating the aerosol by vaporisation of the source liquid stored in the reservoir tank 33.
  • the susceptor 34 is intended for heating via induction, which will be described further below.
  • a liquid transfer or delivery arrangement such as a wick or other porous element 35 may be provided to deliver source liquid from the reservoir 33 to the heater 34.
  • a wick 5 may have one or more parts located inside the reservoir 33, or otherwise be in fluid communication with the liquid in the reservoir 33, so as to be able to absorb source liquid and transfer it by wicking or capillary action to other parts of the wick 35 that are adjacent or in contact with the heater 34. This liquid is thereby heated and vaporised, to be replaced by new source liquid from the reservoir for transfer to the heater 34 by the wick 35.
  • the wick may be thought of as a bridge, path or conduit between the reservoir 33 and the heater 34 that delivers or transfers liquid from the reservoir to the heater. Terms including conduit, liquid conduit, liquid transfer path, liquid delivery path, liquid transfer mechanism or element, and liquid delivery mechanism or element may all be used interchangeably herein to refer to a wick or corresponding component or structure.
  • a heater and wick (or similar) combination is sometimes referred to as an atomiser or atomiser assembly, and the reservoir with its source liquid plus the atomiser may be collectively referred to as an aerosol source.
  • Other terminology may include a liquid delivery assembly or a liquid transfer assembly, where in the present context these terms may be used interchangeably to refer to a vapour-generating element (vapour generator) plus a wicking or similar component or structure (liquid transport element) that delivers or transfers liquid obtained from a reservoir to the vapour generator for vapour / aerosol generation.
  • vapour generator vapour generator
  • wicking or similar component or structure liquid transport element
  • the wick 35 may be an entirely separate element from the heater 34.
  • the heater 34 may be configured to be porous and able to perform at least part of the wicking function directly (a metallic mesh or foam, for example).
  • the susceptor 34 (sometimes called susceptor heating element or heater) may comprise a capillary structure configured to wick a liquid aerosol generating substrate.
  • the vapour generating element may be an inductively heated susceptor element 34 that operates by inductive heating to heat and vapourise an aerosol generating material.
  • an atomiser can be considered as one or more elements that implement the functionality of a vapour-generating or vaporising element able to generate vapour from source liquid delivered to it, and a liquid transport or delivery element able to deliver or transport liquid from a reservoir or similar liquid store to the vapour generator by a wicking action I capillary force.
  • An atomiser is typically housed in a cartridge component of a vapour generating system.
  • liquid may be dispensed from a reservoir directly onto a vapour generator with no need for a distinct wicking or capillary element.
  • the liquid delivery element 35 may comprise any suitable wicking material.
  • it may be made from fibres which are grouped, bunched, wadded, woven or non-woven into a fabric or a fibrous mass, where interstices are present between adjacent fibres to provide a capillary effect for absorbency and wicking.
  • fibre materials include cotton (including organic cotton), ceramic fibres and silica fibres. Other suitable materials are not excluded and will be apparent to the skilled person.
  • the liquid delivery element 35 comprises a solid porous element, such as a porous ceramic material or a porous foam.
  • a porous ceramic material comprises a network of tiny pores or interstices which is able to support capillary action and hence provide a wicking capability to absorb liquid from a reservoir and deliver it to the vicinity of the heater for vaporisation.
  • the cartridge 30 comprises a housing 36 defining a mouthpiece or mouthpiece portion having an opening or air outlet 12 through which a user may inhale the aerosol generated by the susceptor 34.
  • the outer surface of the housing 36 may be shaped to accommodate a user’s lips to enable a user to more easily form a seal around the air outlet 12 with their mouth.
  • the cartridge 30 may not include or otherwise define a mouthpiece. Instead, in some examples, a mouthpiece may connect to the cartridge 30, or the cartridge 30 may be received within a cavity of the device part 20 (e.g. defined by the induction assembly 40) such that the cartridge 30 is entirely enclosed by the device part 20 which itself provides or is attached to a mouthpiece.
  • the power component or device part 20 (sometimes called a device or control part because it typically contains control circuitry) includes a power supply 25, such as a cell or battery, and which may be re-chargeable, to provide power for electrical components of the system 10, in particular to apply power to an induction element or work coil 42 (described in more detail below) to inductively heat the susceptor 34.
  • a power supply 25 such as a cell or battery, and which may be re-chargeable, to provide power for electrical components of the system 10, in particular to apply power to an induction element or work coil 42 (described in more detail below) to inductively heat the susceptor 34.
  • controller 28 such as a printed circuit board and/or other electronics or circuitry for generally controlling the aerosol delivery system 10.
  • the control electronics I circuitry 28 operates the induction element 42 using power from the power supply 25 when vapour is required, for example in response to a signal indicative of a user pressing a button (not shown) or from an air pressure sensor or air flow sensor (not shown) that detects an inhalation on the system 10 during which air enters through one or more air inlets 14 (e.g. provided at a junction between the device part 20 and the cartridge 30).
  • the induction element 42 When the induction element 42 is operated, the induction element 42 inductively heats the susceptor 34 to a suitable temperature in order to vaporise source liquid delivered from the reservoir 33 by the liquid delivery element 35 to generate the aerosol, and this is then inhaled by a user through the opening 12 in the mouthpiece of the cartridge housing 36.
  • the aerosol is carried from the aerosol source to the mouthpiece outlet 12 along one or more air channels defining an air pathway 16 (for example, see the arrows depicted in Figure 1) that connect the air inlet 14 to the aerosol source to the air outlet when a user inhales on the air outlet 12.
  • the device part 20 comprises a frame, or support structure 22 (sometimes called a device frame or support) which is configured to support, retain or position various components of the device part 20, including the power supply 25 and the control circuitry 28.
  • the frame 22 may also support other components not shown such as a wired connection port and PCB for charging (and optionally, communication), user interface elements (e.g. buttons, LEDs, display screens, haptic feedback units), and I or wireless communication components.
  • the frame 20 can be provided by a single component, or may comprise a number of frame components which are combined to form the frame 20.
  • the device part 20 comprises an outer housing 24 and I or an end cap 26.
  • the outer housing 24 may be a tubular structure or wrap, which is configured to contain the components of the device part 20.
  • the frame 22 containing the power supply 25 and the control circuitry 28 can be inserted into the outer housing 24, or the outer housing 24 can be provided around the outside of the frame 22.
  • an end cap 26 is provided at one end of the outer housing 24 (e.g. after insertion of the frame 20 containing the power supply 25 and the control circuitry 28) to seal the outer housing 24 (e.g. to protect the components on the inside of the outer housing 24 from the ingress of water and dust).
  • the induction element or work coil 42 may be provided as part of an induction assembly 40 which comprises a support structure or housing 44 which is configured to position or contain the induction element or work coil 42 (i.e. the support structure 44 supports the induction element 42).
  • the induction assembly 40 is formed by integrally molding the support structure 44 around the inductive work element 42, whereas in other examples the support structure 44 provides a scaffolding to which the inductive work element is attached or fixed.
  • the induction assembly 40 comprises a support 44 having a tube portion disposed about said longitudinal axis of the induction element 42, wherein the tube portion comprises an inner wall and an outer wall, wherein the induction element 42 is provided between the inner wall and the outer wall of the tube portion, and wherein the inner wall defines a receiving cavity 49 in which a susceptor 34 is at least partly located, when a portion of the cartridge 30 (i.e. an insertion portion) comprising the susceptor 34 (or a part of the susceptor 34) is inserted into the receiving cavity 49.
  • the induction assembly 40 comprises a ferrite shield 48, such as a film, foil or sheet, which may be retained in position by the support structure 44.
  • a ferrite shield 48 such as a film, foil or sheet, which may be retained in position by the support structure 44.
  • the ferrite shield may be inserted or embedded into the support structure 44, or wrapped around an outer surface of the support structure 44.
  • a ferrite shield can be used to inhibit magnetic flux in the direction of the shield from the induction element 42, when power is supplied to the induction element 42.
  • the ferrite shield 48 is disposed about a circumference of the induction element 42. In some examples, the ferrite shield 48 comprises a film, foil or sheet. In some examples, the ferrite shield 48 is inserted or embedded into a support 44 for the induction element 42. In some examples, the ferrite shield 48 comprises a sleeve surrounding a support 44 for the induction element 42.
  • the induction assembly 40 is a fixed or permanent component of the device part 20.
  • the support structure 44 can be integrally formed with the frame 22 of the device part 20.
  • the induction assembly 40 and the device part 20 are separate connectable parts detachable from one another by separation in a direction parallel to the longitudinal axis of aerosol delivery system 10.
  • the components 20, 40 are joined together when the system 10 is in use by cooperating engagement elements (for example, a screw or bayonet fitting) which provide mechanical and electrical connectivity between the power section 20 and the induction assembly 40.
  • the electrical connectivity can be required in order to provide electrical power to the induction element 42 when the control circuitry 28 determines that power should be supplied to the induction element 42.
  • the control circuitry is at least for controlling the supply of power to the induction element, wherein the control circuitry is configured to drive the induction element to induce current flow in the susceptor to inductively heat the susceptor and so vaporise a portion of the aerosol generating substrate in the vicinity of the susceptor.
  • an interchangeable induction assembly 40 improves the ease of replacing the induction assembly 40 in the case of damage or wear, as well as potentially also allowing for customisation of a system 10 by allowing a user to replace an induction assembly with a different induction assembly with an alternate configuration for operation with a different susceptor 34 arrangement (e.g. provided by a cartridge 30 having a different configuration).
  • the induction assembly 40 may seal an end of the outer housing 24 (e.g. to protect the components on the inside of the outer housing 24 from the ingress of water and dust).
  • the induction assembly 40 may be provided at the opposite end of the outer housing 24 to the end having the end cap 26.
  • the induction assembly 40 may connect to the frame 22 and I or the outer housing 24 in such a way that a liquid seal is formed preventing liquid from flowing into the cavity formed by the outer housing 24, end cap 26 and the induction assembly 40.
  • the device part comprises a second end cap which is fixed to the outer housing 24 and I or frame 22 between the frame 22 and the induction assembly 40.
  • a second end cap may be configured to facilitate the attachment of the induction assembly 40 to the device part 20.
  • the induction assembly 40 may facilitate the connection between the device part 20 and the cartridge 30.
  • the induction assembly 40 and the cartridge 30 may include cooperating engagement elements (for example, a screw or bayonet fitting) which provide mechanical (and optionally electrical) connectivity between the induction assembly 40 and the cartridge 30 to indirectly connect the cartridge 30 to the device part 20 (including electrical connectivity if necessary) via the induction assembly 40.
  • the cartridge 30 and induction assembly 40 are shaped (e.g. the cartridge housing 36 and the induction support 44, respectively) so that when they are connected, there is an appropriate exposure of the susceptor 34 to flux generated by the induction element 42 for the purpose of generating current flow in the material of the heater.
  • the cartridge 30 comprises an insertion portion 61 defining at least in part an aerosol chamber 63 and a substrate region 65.
  • the insertion portion 61 is defined by a longitudinal axis corresponding to an insertion direction.
  • the insertion portion 61 is inserted into the induction assembly 40 by aligning the insertion portion 61 with a corresponding cavity or recess of the induction assembly 40 and moving the insertion portion 61 in the insertion direction towards the induction assembly 40.
  • the insertion portion 61 may alternatively be called an engagement portion, for example.
  • the cartridge 30 may be disengaged from the induction assembly 40 by moving the cartridge in the opposite direction to the insertion direction.
  • a susceptor 34 is provided within the insertion portion 61.
  • the susceptor comprises a planar surface 341 separating the aerosol chamber 63 from the substrate region 65.
  • the planar surface 341 is provided parallel to the longitudinal axis.
  • the planar surface 341 separating the aerosol chamber 63 from the substrate region 65 it is meant that the planar surface define the border of the aerosol chamber 63 which is on the side adjacent (or closest to) the substrate region 65.
  • the susceptor 34 comprises a planar element which acts as a wall between the aerosol chamber 63 and the substrate region 65 (e.g. a thin metal sheet of around 20 pm to 70 pm); whilst in other examples, the susceptor 34 comprises a block of material which additionally is configured to retain and/ or transport an aerosol generating substrate. In these examples, the block extends into the substrate region 65 (and may fill the substrate region 65) and comprises a planar surface 341 adjacent to the aerosol chamber 63 which marks the extent of the substrate region 65 towards the aerosol chamber 63.
  • the susceptor 34 divides the aerosol chamber 63 from the substrate region 65 within the insertion portion 61.
  • the aerosol chamber 63 comprises a channel extending through (at least) the insertion portion 61 of the cartridge 30 (the channel forming part of the air pathway 16), with a periphery of the aerosol chamber 63 defined by a housing 36 providing the insertion portion 61 and the planar surface 341 of the susceptor 34.
  • a periphery of the substrate region 65 is defined by the housing 36 providing the insertion portion 61 and a susceptor 34 (e.g.
  • the planar surface 341 extends through a centre of a cross-section of the insertion portion 61 which is perpendicular to the longitudinal axis.
  • the insertion portion 61 can be considered to be defined by a peripheral boundary or circumference, with a cross-sectional shape perpendicular to the longitudinal axis (i.e. the insertion direction).
  • the outer cross-sectional shape of the insertion portion 61 perpendicular to the longitudinal axis may be constant for substantially the whole length of the insertion portion 61.
  • the outer cross-sectional shape may be constant except for the end of the insertion portion 61 which is join or connected with the remainder of the cartridge housing 36 (e.g. the mouth-end or reservoir portion), or where the end of the insertion portion 61 that defines an end of the cartridge 30 (e.g. the end of the insertion portion 61 which is first inserted into the induction assembly 40).
  • the cross-section of the insertion proportion 61 comprises an elliptical or circular periphery, wherein the planar surface is co-parallel with a diameter of the crosssection.
  • the insertion portion 61 may be formed in a rod shape having a circular or elliptical shape perpendicular to an elongation direction.
  • the portion of the susceptor 34 providing the planar surface 341 is aligned with a diameter such that the planar surface intersects the centre of the circular or elliptical shape. As above, this can ensure the aerosol generation zone of the susceptor 34 is substantially central to an induction element 42 which surrounds the insertion portion 61.
  • the insertion portion 61 comprises an air inlet for introducing air into the aerosol chamber 63 and I or an outlet allowing aerosol to leave the aerosol chamber 63 (the aerosol chamber 63 providing part of the air pathway 16).
  • air in the air pathway 16 is directed into the air inlet (e.g. from a channel between the induction assembly 40 and the cartridge 30) and travels through the aerosol chamber 63 in which the aerosol can be formed, before the aerosol (or vapour) entrained in the air is drawn out of the aerosol chamber 63 towards the outlet 16 of the system 10.
  • an air inlet for introducing air into the aerosol chamber 63 may be provided by a different portion of the housing 36.
  • An attractive feature of induction heating is that no electrical connection to the conducting item is needed; the requirement instead is that a sufficient magnetic flux density is created in the region occupied by the item.
  • this is beneficial since a more effective separation of liquid and electrical current can be effected.
  • Induction heating is effective for the direct heating of an electrically conductive item, as described above, but can also be used to indirectly heat non-conducting items.
  • the need is to provide heat to liquid in the porous wicking part of the atomiser in order to cause vaporisation.
  • the electrically conducting item is placed adjacent to or in contact with the item in which heating is required, and between the work coil and the item to be heated. The work coil heats the conducting item directly by induction heating, and heat is transferred by thermal radiation or thermal conduction to the non-conducting item.
  • the conducting item is termed a susceptor.
  • the heating component can be provided by an electrically conductive material (typically metal) which is used as an induction susceptor to transfer heat energy to a liquid proximal to the atomiser (e.g. held by a wick 35 and I or the susceptor 34 itself).
  • an electrically conductive material typically metal
  • induction susceptor to transfer heat energy to a liquid proximal to the atomiser (e.g. held by a wick 35 and I or the susceptor 34 itself).
  • the susceptor comprises a planar element, the planar element having a thickness in the range of one or more of 20 pm to 70 pm, 30 pm to 60 pm, and 40 pm to 55 pm.
  • the thickness of a sheet providing the susceptor 34 may be in the range of about 20 pm to about 70 pm, for example about 30 pm to about 60 pm, or about 40 pm to about 55 pm. These values may be the total thickness of the sheet including any supporting elements or coatings. If the thickness is insufficient, the heater may lack adequate structural integrity, although this may be compensated by additional components (e.g. support components).
  • a susceptor for a heater 34 has a simple rectangular shape or profile.
  • the susceptor 34 can be formed of a sheet having a rectangular shape with a length 5 to 50 mm) and width (e.g. 2 to 15 mm) that are significantly greater than a thickness of the sheet (e.g. 20 pm to 70 pm).
  • an element providing a susceptor may have an alternative shape such as a non-rectangular, polygonal shape or a circular or elliptical shape . This may be particularly useful where heating is intended to be focussed at particular zones or portions within the cartridge 30.
  • the susceptor can be provided with a shape that corresponds to zones which are incident with relatively large magnetic flux from the induction element.
  • the susceptor 34 is not provided by a sheet (i.e. defined by two dimensions and a thickness of a relatively small order of magnitude in comparison to the two dimensions) and may, for example, be instead provided by a block element having a thickness of a similar order of magnitude to the two dimensions defining the planar surface of the susceptor 34; the element or block formed of a suitable electrically conductive material, with adequate resistance to enable heating by induction effects via induced eddy currents.
  • the susceptor 34 may comprise an inductively heatable material such as wire wool or mesh (e.g. a (ferritic) stainless steel mesh) or a metal foam (e.g. nickel foam or cupro-nickel foam) formed into an appropriate shape.
  • a block e.g. provided by stainless steel mesh or nickel foam
  • a block may have a thickness in the range of 0.5 to 5 mm.
  • the stainless steel mesh or nickel foam may have a thickness in the range of 1.5 to 3 mm.
  • a block element may have a shape such as a flat slab (e.g. a cuboid), with a thickness as described above.
  • a block element may be formed in the shape of a semi-circle rod (e.g. a rod having a semi-circular cross-section perpendicular to the elongation direction of the rod).
  • a semi-circle rod e.g. a rod having a semi-circular cross-section perpendicular to the elongation direction of the rod.
  • Such a semi-circle rod may have a profile or shape matching a corresponding cavity in the insertion portion 61 (e.g. the substrate region 65).
  • a suitable block element may be formed by pressing a steel mesh into a required shape or by forming a nickel foam within a mould having a required shape.
  • the susceptor 34 (sometimes called the susceptor heating element 34 or heater 34) comprises a plurality of apertures extending through the susceptor 34. Said apertures may be called perforations or holes.
  • the plurality of perforations may be holes cut or punched through the material of a susceptor 34 formed from a planar element (e.g. a sheet of material). Each hole is small compared to the total external surface area of the susceptor 34 (e.g. the plane of a sheet).
  • the holes are relatively closely packed and evenly distributed over the surface of the susceptor 34 so that many holes are included.
  • the holes may be circular, for example, or may be elongated or slot-shaped.
  • the purpose of the holes is to enable the generated vapour to more easily escape from the atomiser (e.g. wick and susceptor) into the aerosol chamber to be collected by the airflow through the aerosol chamber.
  • the atomiser e.g. wick and susceptor
  • the generated vapour can flow through the perforations into the free space of the air pathway 16 adjacent to the heater 34.
  • the planar surface 341 of the susceptor 34 is defined by a length and a width (e.g. when the planar surface is a rectangle), wherein the length is greater than the width.
  • the length is parallel to the longitudinal axis of the induction element 42.
  • the number density of the plurality of apertures varies along the length and I or along the width of the planar surface. By the number density it is meant the number of apertures per unit area. In some examples, the number density of the plurality of apertures increases monotonically along a length of the susceptor 34. For example, the number density may increase from an end of the susceptor 34 close to the reservoir 33 towards an end of the susceptor 34 away from the reservoir 33.
  • the number density of the plurality of apertures increases or decreases along the width from edges of the planar surface 341 to a centre of the planar surface 341 .
  • the number density of the plurality of apertures increases from the edge of the susceptor 34 (perpendicular to the ends defining the length) towards the centre of the susceptor 34.
  • the wick 35 comprises an inductively heatable material such as a stainless steel mesh or a nickel foam.
  • Said wick 35 formed of an inductively heatable material may also provide the heater 34 component (e.g. a combined wick-heater atomiser) or may be in addition to the heater 34 (e.g. the wick part of an atomiser formed of a wick 35 and heater 34).
  • the heater 34 component e.g. a combined wick-heater atomiser
  • the wick 35 When the wick 35 is placed in the flux of the magnetic field, the field penetrates the item and induces electric eddy currents. These flow in the item, and generate heat according to current flow against the electrical resistance of the item via Joule heating, in the same manner as heat is produced in a resistive electrical heating element by the direct supply of current.
  • the wick 35 is able to contribute to the heating of the liquid and may also retain residual or latent heat between puffs, which can act to reduce the amount of energy or time required to heat the susceptor 34 to a vaporisation temperature on a subsequent puff.
  • the wick 35 may have a large mass, in comparison to the susceptor 34, which acts to store latent heat, while the relatively low mass of the susceptor 34 allows for rapid heating of the susceptor 34.
  • a stainless steel mesh or nickel foam providing a wick 35 has a shape corresponding to the susceptor 34.
  • a wick 35 and a susceptor 34 may comprise abutting surfaces which are configured to ensure reasonable contact between the wick 35 and the susceptor 34 when the wick 35 and susceptor 34 are provided in the insertion portion 61.
  • the wick 35 can abut a second susceptor surface of the susceptor 34 on the opposing side of the susceptor 34 to the planar surface 341.
  • the wick 35 can aid in positioning the susceptor 34 by, for example, exerting a retaining force on the susceptor 34 caused by compression of the wick 34 and positioning of the susceptor 34 between the wick 35 and an element of the housing 36 defining the insertion portion 61 to push the susceptor 34 against the element of the housing 36.
  • a liquid transport element 35 (or wick) provides liquid to a second susceptor surface on an opposing side of the susceptor 34 to the first susceptor surface.
  • liquid can be supplied to the susceptor 34 via the liquid transport element 35 and then when the liquid is vaporised and the liquid is able to pass through the susceptor 34 (e.g. by one or more apertures extending through the susceptor 34) from the second susceptor surface to the first planer surface 341.
  • the liquid transport element 35 comprises a semi-circle rod, wherein a flat surface of the semi-circle rod abuts the second susceptor surface.
  • a semi-circle rod it is meant a rod having a semi-circular cross-section perpendicular to the elongation direction of the rod. It will be appreciated that such a rod has a flat surface defining a diameter of the circle and a curved surface defining a 180° arc of a circle.
  • the curved surface is configured to correspond to a shape of the substrate region 65 such that an interference fit is provided between the liquid transport element 35 and at least a portion of the housing defining the substrate region 65, thereby aiding in retaining the liquid transport element 35 in place.
  • the cartridge 30 and induction assembly 40 are shaped so that a portion of the cartridge 30 is received within a cavity or void 49 of the induction assembly 40 when the cartridge 30 and induction assembly 40 are connected.
  • Said cavity or void 49 may be termed a receiving cavity 49.
  • the receiving cavity 49 is defined by a housing or support 44 of the induction assembly 40.
  • the support 44 may comprise an inner surface defining the shape of the receiving cavity 49.
  • a portion of the support 44 defining part of the receiving cavity 49 may be a tubular support.
  • the induction element 42 is provided in the form of a spiral or helical induction element 42.
  • the induction element 42 is formed substantially in a coil surrounding and extending along an axis.
  • the axis around which the induction element 42 is formed is parallel with the longitudinal axis of the system 10.
  • the induction element 42 is formed by of a conductive element or component embedded within or provided on a surface of the support 44 defining the receiving cavity 49 (e.g. within a tubular part of the support 44).
  • the induction element 42 is provided such that a portion of the cartridge 30 inserted into the receiving cavity 49 is within the coil of the induction element 42.
  • a portion of the cartridge 30 comprising the susceptor 34 is provided within the coil of the induction element 32 when the cartridge 30 is received in the receiving cavity.
  • an AC electric current is passed through the helical induction coil 42 which results in the generation of a varying magnetic field which generates eddy currents within a susceptor 34 of a cartridge 30 thereby rapidly heating the susceptor 34, which may result in aerosol being generated.
  • the coil of the induction element 42 may have a constant number of turns per unit length (i.e. along the axis) or the number of turns per unit length may be different at different sections of the coil of the induction element 42.
  • a coil can be considered to have a total length which can be subdivided into two or more sections.
  • a coil comprises two equal sections (i.e. the length of the first section is the same as the length of the first section, and the number of turns per unit length in the first section is the same as the number of turns per unit length in the second section).
  • the number of turns per unit length may be greater in the first section than the number of turns per unit length in the second section, or vice versa.
  • a coil may comprise a plurality of sections and wherein at least some of the sections may have a different or the same number of turns per unit length.
  • the induction element 42 comprises two or more separate and distinct coils, each of which may have a same or different number turns per unit length and I or total length. The variation in the number of turns can increase or decrease the rate at which the susceptor 34 is heated (e.g. the rate at which the susceptor can reach a maximum operating temperature). Such an arrangement may provide asymmetrical heating of susceptor materials within a cartridge 30 along the length of the cartridge which is received within the receiving cavity 49, if desired.
  • the induction assembly 40 comprises a first induction element 42 and a second induction element both of which are disposed about the same longitudinal axis.
  • a first portion of the susceptor 34 is located at least partly within the first induction element and a second portion of the susceptor 34 is located at least partly within the second induction element.
  • the first and second induction elements are operable to induce current flow in the second portion of the susceptor to inductively heat the first and second portions of susceptor 34, respectively.
  • the first and second induction elements may have a same length, diameter and number of turns per unit length (including any variation in the number of turns per unit length), or alternatively one or more of the length, diameter, number of turns per unit lengths (including variation in the number of turns per unit length) may differ between the different induction elements.
  • each additional induction element may be the same as, or differ from, one or more other induction elements.
  • the first portion of the susceptor 34 and the second portion of the susceptor 34 are portions of a single susceptor.
  • the susceptor 34 may be a tube component extending into both the first and second induction elements.
  • the induction element 42 is formed by a resistive wire, such as a nickel or cupronickel wire, which is configured or arranged into a shape such as a spiral or helix (e.g. a spiral coil or a helical coil).
  • the induction element is a litz coil.
  • a resistive wire providing the induction element 42 is provided in a support 44 which acts to retain the resistive wire in a particular shape (e.g. a three-dimensional spiral).
  • the resistive wire may be embedded in the support.
  • a resistive wire providing the induction element 42 is substantially free-standing in that the resistive wire is able to support an orientation and configuration with respect to an anchor location (i.e. where the resistive wire engages a support 44).
  • the resistive wire may be a suitably rigid material (e.g. a suitably thick wire) that it is able to maintain a configuration throughout continued use.
  • the induction element 42 may be printed or deposited on a portion of a substrate or support 44.
  • a laser is used to activate the surface of the support 44, which may comprises a thermoplastic material such as polyetheretherketone (PEEK) which may have been doped with a metallic inorganic compound.
  • PEEK polyetheretherketone
  • the laser creates one or more laser activated regions upon the support 42 which can then be further metallised using e.g. an electroless plating process to build up one or more conductive layers of e.g. copper.
  • an induction element 42 may be deposited upon a tubular portion of a support 44 so as to form a spiral induction coil or a helical induction coil (i.e. a spiral coil or a helical coil).
  • the portion of the induction assembly 40 containing the induction element 42 is part of the support structure 44 or housing (sometimes called the support 44 as above) of the induction assembly 40.
  • the support structure 44 may surround the induction element 42 thereby providing a protective housing for the induction element and I or to support or maintain the position of the induction element 42 within the induction assembly 40.
  • at least a portion of the induction element 42 may not be covered by the support structure 44. In such examples, the induction element 42 may be exposed to ambient air.
  • the support 44 can provide other functionality such as facilitating the attachment of the induction assembly 40 to the control part 20.
  • the distance separating the susceptor 34 (e.g. the outer surface of the susceptor 34) from the induction element 42 (e.g. the inner diameter of the spiral shape of the induction element 42) is sometimes called the coupling distance.
  • the susceptor 34 and the induction element 42 effectively form a pair in which the induction element 42 is inductively coupled to the susceptor and is able to transmit or transfer energy to the susceptor 34 when a current is applied to the induction element 42.
  • the coupling distance relates to the distance across which energy is transferred from the induction element 42 to the susceptor. The further away the susceptor 34 is (i.e. the larger the coupling distance), the greater the loss in energy.
  • the coupling distance is based on the diameter of the induction element 42 (e.g. because the susceptor 34 is received within the induction element 42) and on the width of the susceptor within the induction element 42.
  • the susceptor 34 is configured to provide a planar surface 341 substantially centrally to the induction coil 42 when the insertion portion 61 is received in the induction assembly 40.
  • the susceptor 34 may be a planar element which intersects a centre of the induction element 42.
  • the coupling distance is different for different portions of the susceptor 34 with the central portion of the planar surface 341 having a maximum distance from the induction element 42 and the edge portion (defining a width of the planar surface 341) having a reduced coupling distance.
  • portions of the susceptor 34 away from the planar surface 341 also have a reduced coupling distance.
  • the coupling distance away from the centre of the planar surface 341 may be dependent on the thickness of any surrounding housing of the insertion portion 61 and the induction element 42 (e.g. a support 44), and also the width of any air gap between the insertion portion 61 and the induction assembly 40), as these factors limit the possible width of the susceptor 34.
  • different portions of the susceptor 34 with different coupling distances are therefore heated differently by the magnetic field.
  • the coupling distance is in the range of less than 5 mm for all portions of the susceptor 34. In some examples, the coupling distance is in the range of less than 3 mm for all portions of the susceptor 34.
  • the aerosol delivery system 10 comprises an air pathway 16 defined in part by a volume between the insertion portion 61 received in the receiving cavity 49 and a surface of the induction assembly 40 defined by the support 44. Said portion of the air pathway 16 is provided between the inlet 14 and a vapour/aerosol generation portion of the air pathway provided within the cartridge 30.
  • the separation (e.g. coupling distance) of the susceptor 34 and the induction assembly 40 can be set at least in part by the width or size of the portion of the air pathway 16 formed between the cartridge 30 and induction assembly 40, with the air pathway 16 in this region of the system 10 needing to be sized to allow adequate air flow.
  • the separation of the cartridge 30 and the induction assembly 40 is in the range of 0.2 mm to 1 mm.
  • an air pathway 16 does not extend between longitudinally extending portions of the insertion portion 61 and the support 44, and the separation of the separation of the insertion portion 61 and the induction assembly 40 is in the range of up to 0.5 mm, and preferably less than 0.2mm.
  • a small separation of the insertion portion 61 and the induction assembly 40 may cause an interference fit to be formed which aids in retaining the cartridge 30 with the induction assembly 40.
  • the Figure 1 design is merely an example arrangement, and the various parts and features may be differently distributed between the power section 20 and the cartridge assembly section 30, and other components and elements may be included.
  • the two sections may connect together end-to-end in a longitudinal configuration as in Figure 1 , or in a different configuration such as a parallel, side-by-side arrangement.
  • the system may or may not be generally cylindrical and/or have a generally longitudinal shape. Either or both sections or components may be intended to be disposed of and replaced when exhausted (the reservoir is empty or the battery is flat, for example), or be intended for multiple uses enabled by actions such as refilling the reservoir and recharging the battery.
  • system 10 may be unitary, in that the parts of the device part 20 (including the induction assembly 40) and the cartridge 30 are comprised in a single housing and cannot be separated.
  • Embodiments and examples of the present disclosure are applicable to any of these configurations and other configurations of which the skilled person will be aware.
  • FIG 2 is an exploded view of an example induction assembly 40 in accordance with the present disclosure.
  • the exploded view of the induction assembly 40 depicts an example support structure or housing 44 (sometimes called support), an induction coil 42 (e.g. an example of an induction element 42), and a ferrite shield 48.
  • the example housing 44 comprises a (tubular) receiving portion 46 and a base portion 45. Aspects of the induction assembly 40 may be as described in relation to Figure 1 .
  • the induction assembly 40 is for use with a cartridge 30 in accordance with the present disclosure.
  • the induction assembly 40 comprises an induction element 42 disposed about a longitudinal axis corresponding to an insertion direction of an insertion portion 61 of the cartridge 30.
  • the induction element 42 is operable to induce current flow in the susceptor 34 to inductively heat the susceptor 34 to aerosolise a portion of the aerosol generating substrate in the vicinity of the susceptor 34.
  • the receiving portion 46 is configured to define the receiving cavity 49 into which a portion of the cartridge 30, containing a susceptor 34, is received when the cartridge 30 and the induction assembly 40 are joined.
  • the receiving portion 46 may have a tubular or annular shape where an inner void is configured to define the receiving cavity 49.
  • the configuration of the receiving portion 46 corresponds to the configuration of the portion of a cartridge 30 received in cavity 49 of the receiving portion 46.
  • the receiving portion 46 may be in the shape of a circularly symmetric tube.
  • the receiving portion 46 may be configured to provide a cavity 49 having a cross-section of the same shape.
  • the cross-section of the receiving portion 46 may be slightly larger than that of the portion of the cartridge 30, in order to allow airflow between the receiving portion 46 and the cartridge 30.
  • the receiving portion 46 of Figure 2 additionally comprises a spiral recess 47 for receiving a spiral coil.
  • the induction assembly 40 is formed by providing an suitable induction element 42 (i.e. a spiral coil in this example) in the spiral recess 47 (and optionally surrounding or sleeving with a ferrite shield 48).
  • the spiral recess 47 of receiving portion 46 may extend between the first and second opposing faces as shown, or the spiral recess 47 may be internal to the housing 44 (i.e. to encapsulate an induction element 42).
  • the receiving portion 46 will not comprise the spiral recess 47, and may instead comprise a recess of a different configuration or a surface upon the induction element 42 can be formed.
  • the thickness of the receiving portion 46 (e.g. thickness of tubular walls) is selected to be equal or to approximately equal the width of the induction element 42 received in the spiral recess 47 (e.g. the diameter of a wire providing a spiral coil). By approximately equal it is meant that the thickness may be slightly less than the width of the induction element 42 (no less than 95% of the width), or slightly more than the support the width of the induction element 42 (no more than 105% of the width). In some examples, the thickness of the receiving portion 46 is selected to provide structural rigidity to the induction assembly 40 and I or support for the induction element 42.
  • the base portion 45 comprises attachment features 43 configured to facilitate the connection of the housing 44 to a control part 20 having corresponding attachment features (i.e. the control part 20 of Figure 1).
  • the attachment features 473 allow an induction assembly 40 to be reversibly connected to a control part, such that the induction assembly 40 can be removed and replaced without damaging the control part or the induction assembly 40.
  • the attachment features 43 may be omitted (e.g. the housing 44 may be integrally formed with a housing of the control part), or the attachment features 43 may be configured to provide a permanent attachment which is not intended to be reversed (i.e. disconnected).
  • the base portion 45 may also facilitate the electronic connection of the induction element 40 to the control part 20.
  • the base portion 45 comprise through holes 41 for respective ends of a wire coil providing the induction element 42, or for electrodes connecting to the induction element 42.
  • said through holes 41 extend from a top surface of the base portion 45 to a bottom surface in order to allow the wire ends or electrodes to pass through the base portion 45 towards the interface with the device part 20.
  • the base portion 45 further comprises one or more channels providing a portion of the air pathway 16.
  • the channel may for example direct, or facilitate, airflow through the base portion 45 and into the receiving cavity 49 defined by the receiving portion 46.
  • a suitable channel may align with a corresponding channel provided by the cartridge 30 (i.e. a channel defined in part by the susceptor 34), such that air may flow from the induction assembly 40 into the channel of the cartridge 30.
  • the channel may extend into a recessed void on the lower side of the base portion (opposite the receiving portion 46) which is configured to allow airflow between the base portion 45 and the device part (e.g. a surface of a housing of a device part as shown in Figure 1).
  • Figure 2 depicts an induction element 42 comprising a wire coil.
  • the wire coil is a length of wire which has been configured or shaped into a spiral coil.
  • the wire coil may be manipulated into the required shape by winding the wire of the coil onto the outer surface of the receiving portion 46 (e.g. by winding the wire into the spiral recess 47).
  • the wire coil further comprises two respective ends 421 which are configured to allow the formation of a circuit for the transmission of power through the wire coil providing the induction element 42.
  • the respective ends 421 may be inserted into through holes 41 of the base portion 45 when the wire coil is combined with the support 44.
  • Figure 2 depicts a ferrite shield 48.
  • the ferrite shield 48 comprises a sleeve which is provided over the receiving portion 46 and induction element 42 (in other words the receiving portion 46 and induction element 42 are inserted into the sleeve of the ferrite shield 48), or the ferrite shield 48 is wrapped around the receiving portion 46 and induction element 42.
  • the ferrite shield 48 acts to block or inhibit magnetic flux in an outward direction from the induction element 42 when a current is applied through the induction element 42.
  • FIG 3 is a exploded perspective drawing of an example cartridge 30 in accordance with the present disclosure.
  • the cartridge 30 may be for use with an induction assembly 40 comprising the support 44 of Figure 2.
  • the cartridge 30 comprises an upper housing 361 , a lower housing 362, a seal 363, a susceptor 34, and a liquid transport element 35 (sometimes called a wick).
  • Various aspects of the cartridge 30 may be as described in relation to Figure 1.
  • the susceptor 34 of Figure 3 comprises a planar element in which a plurality of apertures 345 have been provided.
  • the susceptor 34 of Figure 3 may be formed by a sheet of material (e.g. nickel, cupronickel, aluminium).
  • the planar element provides a planar surface 341 which is defined by a length and a width, wherein the length is greater than the width.
  • the susceptor 34 is received with the insertion portion 61 of the cartridge 30 such that the length is parallel to the longitudinal axis of the insertion portion 61 corresponding to the insertion direction.
  • the length is in the range of 5 mm to 50 mm.
  • the width is in the range of 2 mm to 15 mm.
  • the liquid transport element or wick 35 of Figure 3 comprises a rod formed of a suitable wicking material (e.g. cotton or a synthetic material).
  • the rod is a semi-circle rod in that the cross-sectional shape of the rod perpendicular to the elongation direction of the rod is a semi-circle.
  • the susceptor 34 of Figure 3 is positioned adjacent to a flat surface of the wick 35 of Figure 3 (defined across the diameter of the semi-circle) such that the wick 35 is able to supply liquid to a surface of the susceptor 34, opposite to the planar surface 341.
  • the planar surface 341 of the susceptor 34 opposite to the surface which is supplied with liquid, defines a portion of the aerosol chamber 63 (not shown) within the insertion portion 61.
  • the susceptor 34 of Figure 3 comprises a plurality of apertures, holes or perforations 345 extending through the material of the susceptor 34.
  • the plurality of perforations 345 may be provided by cutting holes or piercing through the material of the susceptor 34. Each hole is small compared to the area of the susceptor.
  • the purpose of the holes 345 is to enable the generated vapour to more easily escape through the susceptor 34 into the air pathway 16 within the susceptor 34 (i.e. the aerosol chamber) to be collected by the airflow through the air pathway 16.
  • the generated vapour can flow inwardly through the perforations 345 into the free space of the air pathway 16 defined by the surface of the susceptor 34.
  • the liquid transport element 35 is formed from a magnetically heatable material, such as a steel mesh or a nickel foam.
  • the liquid transport element 35 can additionally heat up in response to the generation of a magnetic field by the induction element 42.
  • the liquid transport element can be formed from a susceptor material.
  • the volume and mass of the liquid transport element 35 is significantly greater (for example, the liquid transport element 35 has a width of 0.5 to 2mm, in contrast to a width of 20pm to 70 pm for the susceptor 34).
  • the liquid transport element 35 takes longer to heat up (e.g.
  • the susceptor 34 can provide rapid heating to a vaporisation temperature due to its lower mass and preferential position, whilst a magnetically heatable liquid transport element 35 can absorb energy which would otherwise be lost, and latent heat, which may raise the ambient temperature of the aerosol generating material between vaporisations leading to a decrease in the amount of heating required for the susceptor 34 to reach a vaporisation temperature for a suitable aerosol generating material.
  • the cartridge 30 of Figure 3 further includes a housing 36 formed of an upper housing 361 , a lower housing 362, and a seal portion 363.
  • the upper housing 361 may instead be called a downstream or mouth-end housing in that it provides the portion of the housing that is towards the mouthpiece outlet 12.
  • the upper housing 361 is configured to have a mouthpiece shape comprising the outlet 12 for a user to inhale through.
  • the lower housing 362 may instead be called an upstream or device-end housing in that it provides the portion of the housing that is towards the inlet 14 of the system 10, and towards the position of the device or control part 20 when the cartridge 30 is connected to a control part 20.
  • the seal portion 363 may instead be called an intermediate portion in that it is provided between the upper housing 361 and the lower housing 362. The seal portion 363 facilitates the connection of the upper housing 361 to the lower housing 363 whilst sealing the reservoir 33 and accommodating a liquid pathway to the substrate region 63 of the insertion portion 61.
  • the upper housing 361 defines an internal volume which is configured to retain a liquid aerosol generating material. In other words, the upper housing 361 provides a reservoir.
  • the lower housing 362 defines a volume (or void) which is configured to receive the susceptor 34 and liquid transport element 35. Said volume is divided into the substrate region 65 and the aerosol chamber 63 by a planar surface 341 of the susceptor 34 provided in the volume (and aligned with a longitudinal axis corresponding to the insertion direction. As such the lower housing 362 defines or comprises the insertion portion 61.
  • the seal portion 363 is configured to be inserted into the upper housing 361 to seal the reservoir 33, to inhibit movement of liquid from the reservoir 33 except via a liquid pathway 367 (which may or may not contain the liquid transport element 35).
  • the seal 363 can be configured to inhibit movement of liquid between walls of the upper housing 361 defining the reservoir 33 adjoining walls of the seal portion 363 (e.g. both an external wall of the upper housing 361 defining an exterior shape of the cartridge 30 and an internal wall defining an airflow channel through the upper housing 361).
  • the seal portion 363 comprises an outlet 365 for the aerosol chamber 63.
  • the outlet 365 is configured to align with an airflow channel of the upper housing 361 when the seal portion 363 is connected to the upper housing 361.
  • the upper and lower housings 361 ,362 may be formed from, for example, plastic materials using conventional materials and manufacturing methods (e.g. injection moulding).
  • the seal portion 363 may be formed from a plastics material as above, or may be formed of a material such as silicon. It will be appreciated that Figure 3 is just one example of a cartridge 30, and that in other examples a suitable housing 36 may be provided by different components in different configurations (e.g. reservoir 33 provided in a lower housing 362 by only the substrate region 65, or the housing 36 not requiring a seal 363 because the features of the seal are provided by the lower housing 362).
  • the lower housing 362 is configured to define the insertion portion of the cartridge 30 which is received into the receiving cavity 49 of the induction assembly 40.
  • the susceptor 34 (and optionally the liquid transport element 35) is provided in the lower housing 362 such that when the cartridge 30 is connected to the induction assembly 40, at least a portion of the susceptor 34 is provided within the induction element 42 (e.g. within a spiral coil of the induction element 42).
  • An induction element 42 as discussed above in relation to Figure 1 and Figure 2, is configured to generate a magnetic field that primarily (or dominantly) extends within the coil of the induction element 42. As a result, the inductive heating is strongest for a susceptor which is placed within the induction element 42.
  • Figure 4A is a schematic cross-sectional view parallel to a longitudinal axis of an example cartridge 30 for use in an aerosol/vapour delivery system 10 in accordance with the present disclosure.
  • Figure 4B shows a schematic cross-sectional view perpendicular to a longitudinal axis of the example cartridge shown in Figure 4A.
  • the cross-sectional view Figure 4B is corresponds to the cross-sectional plane through the insertion portion 61 of the cartridge 30 indicated in Figure 4A by a dotted line provided with arrows labelled “A” at each end of the dotted line.
  • the cartridge 30 of Figures 4A and 4B comprises one or more liquid flow channels 37, and a sub-reservoir 331.
  • the one or more liquid flow channels 37 and sub-reservoir 331 may be implemented with any of the cartridge 30 embodiments described in relation to Figures 1 and 3.
  • the remaining aspects of the example cartridge 30 of Figures 4A and 4B are as described in relation to Figures 1 to 3 and may not be described again in detail.
  • the liquid transport element 35 in order to ensure that liquid is drawn into the liquid transport element 35, the liquid transport element 35 is configured to cause a capillary effect having a capillary drive force that is stronger than the capillary drive force of the liquid flow channel 37.
  • the liquid transport element 35 may be formed of a material having channels or pores of a porous network which are smaller in dimension (e.g. width) than the width of the one or more liquid flow channels 37.
  • the lower housing 361 can comprise a plurality of ribs 39 defining the liquid flow channels 37.
  • each liquid flow channel 37 may be defined by two adjacent ribs of the plurality of ribs 39. Said ribs 39 defining the path of the channel 37.
  • the width of the channel 37 may be the separation distance of the two ribs (e.g. two adjacent ribs 39 may be separated by a distance in the range of 0.1 mm to 1 mm.
  • each rib 39 may have a width in the range of 0.1 mm to 1 mm.
  • the sub-reservoir 331 sometimes called a secondary reservoir or supplementary reservoir, comprises a cavity or void which is configured to retain an amount of liquid aerosol generating material.
  • the sub-reservoir 331 is provided at an opposing end of the liquid transport element 35 (or susceptor 34 where the susceptor 34 is configured to provide the function of the liquid transport element 35) to the reservoir 33.
  • the sub-reservoir 331 is positioned such that after vaporisation of aerosol generating material, the liquid transport element 35 is able to absorb, or receive, liquid from both the reservoir 33 and the sub-reservoir 331. This may improve the distribution of liquid aerosol generating material along the length of liquid transport element 35 (e.g. in contact with the susceptor 34).
  • the sub-reservoir 331 is configured to hold a volume of liquid in the range of 0.005 ml to 0.1 ml (e.g. the total volume of the sub-reservoir 331). In some examples, the sub-reservoir 331 is configured to hold a volume of liquid in the range of 0.01 ml to 0.05 ml. In some examples, the sub-reservoir 331 is configured to hold a volume of liquid in the range of 0.015 ml to 0.02 ml.
  • the housing 36 may be a body having a passage extending between two openings in opposing end faces of the body.
  • the passage provides a portion of the air pathway 16 of the system 10 and includes the aerosol chamber 63.
  • the susceptor 34 provides a planar surface 341 defining a boundary of the aerosol chamber 63.
  • the susceptor 34 can comprise a planar element aligned to intersect a centre of the cartridge 30 and parallel to a longitudinal axis corresponding to an insertion direction.
  • the openings in the opposing end faces of the body may be circular or elliptical apertures or may be any other shape (e.g. polygonal, or a combination of curved and straight edges), and the outer surface of the passageway may be defined by walls (including the planar surface 341 provided by the susceptor 34) which extend between the periphery of each of the openings.

Landscapes

  • Disinfection, Sterilisation Or Deodorisation Of Air (AREA)

Abstract

Un système de distribution d'aérosol (10) comprenant une cartouche (30) destinée à être utilisée pour générer un aérosol à partir d'un substrat de génération d'aérosol est décrit. La cartouche comprend une partie d'insertion définissant au moins en partie une chambre d'aérosol et une région de substrat, la partie d'insertion étant définie par un axe longitudinal correspondant à une direction d'insertion. La cartouche comprend également un suscepteur (34) disposé à l'intérieur de la partie d'insertion, le suscepteur comprenant une surface plane séparant la chambre d'aérosol de la région de substrat. La surface plane est disposée parallèlement à l'axe longitudinal. En outre, un ensemble d'induction (40), un embout buccal et une partie dispositif (20) destinés à être utilisés dans le système de distribution d'aérosol, et un procédé de génération d'un aérosol à partir d'un substrat de génération d'aérosol dans le système de distribution d'aérosol sont décrits.
PCT/GB2025/050329 2024-02-23 2025-02-20 Système de distribution d'aérosol Pending WO2025176991A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP24159465.4 2024-02-23
EP24159465.4A EP4606239A1 (fr) 2024-02-23 2024-02-23 Système de distribution d'aérosol

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Publication Number Publication Date
WO2025176991A1 true WO2025176991A1 (fr) 2025-08-28

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170027233A1 (en) * 2014-05-21 2017-02-02 Philip Morris Products S.A. Aerosol-generating system comprising a planar induction coil
US20170164657A1 (en) * 2014-07-11 2017-06-15 Philip Morris Products S.A. Aerosol-forming cartridge comprising a tobacco-containing material
US20180168226A1 (en) * 2015-08-17 2018-06-21 Philip Morris Products S.A. Aerosol-generating system and aerosol-generating article for use in such a system
US20210204604A1 (en) * 2018-05-25 2021-07-08 Philip Morris Products S.A. Susceptor assembly for aerosol generation comprising a susceptor tube
US20220225670A1 (en) * 2021-01-18 2022-07-21 Altria Client Services Llc Heat-not-burn (hnb) aerosol-generating devices and capsules
US20220408805A1 (en) * 2019-11-29 2022-12-29 Nicoventures Trading Limited Electronic aerosol provision system
US20230389611A1 (en) * 2020-10-29 2023-12-07 Jt International Sa A Cartridge for an Aerosol Generating Device, an Aerosol Generating Device and an Aerosol Generating System

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170027233A1 (en) * 2014-05-21 2017-02-02 Philip Morris Products S.A. Aerosol-generating system comprising a planar induction coil
US20170164657A1 (en) * 2014-07-11 2017-06-15 Philip Morris Products S.A. Aerosol-forming cartridge comprising a tobacco-containing material
US20180168226A1 (en) * 2015-08-17 2018-06-21 Philip Morris Products S.A. Aerosol-generating system and aerosol-generating article for use in such a system
US20210204604A1 (en) * 2018-05-25 2021-07-08 Philip Morris Products S.A. Susceptor assembly for aerosol generation comprising a susceptor tube
US20220408805A1 (en) * 2019-11-29 2022-12-29 Nicoventures Trading Limited Electronic aerosol provision system
US20230389611A1 (en) * 2020-10-29 2023-12-07 Jt International Sa A Cartridge for an Aerosol Generating Device, an Aerosol Generating Device and an Aerosol Generating System
US20220225670A1 (en) * 2021-01-18 2022-07-21 Altria Client Services Llc Heat-not-burn (hnb) aerosol-generating devices and capsules

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