WO2025125511A1

WO2025125511A1 - Aerosol provision device

Info

Publication number: WO2025125511A1
Application number: PCT/EP2024/086074
Authority: WO
Inventors: Marcus Hartley
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-12-14
Filing date: 2024-12-12
Publication date: 2025-06-19
Anticipated expiration: 2026-06-14
Also published as: GB202319164D0

Abstract

An aerosol provision device (100) for generating an aerosol from aerosol-generating material is provided. The aerosol provision device (100) comprises a receptacle (105) defining a heating zone (114) for receiving an article (300) comprising aerosol-generating material, a heating arrangement (199) configured to heat the heating zone (114) to generate an aerosol from the aerosol-generating material and a pressure chamber (134) arranged to pressurise the aerosol.

Description

AEROSOL PROVISION DEVICE

Technical Field

The present invention relates to an aerosol provision device for generating an aerosol from aerosol-generating material. The present invention also relates to an aerosol provision system and a method of generating an aerosol for inhalation by a user.

Background

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

Summary

In accordance with embodiments described herein, there is provided an aerosol provision device for generating an aerosol from aerosol-generating material comprising: a receptacle defining a heating zone for receiving an article comprising aerosol-generating material; a heating arrangement configured to heat the heating zone to generate an aerosol from the aerosol-generating material; and a pressure chamber arranged to pressurise the aerosol.

In an embodiment of any of the above, the pressure chamber includes the receptacle.

In an embodiment of any of the above, the aerosol provision device comprises a selectively openable outflow valve arranged to selectively allow aerosol to flow from the pressure chamber.

In an embodiment of any of the above, the selectively openable outflow valve is puff-actuated.

In an embodiment of any of the above, the aerosol provision device is arranged to determine that the aerosol has reached an operating threshold pressure and to permit operation of the outflow valve responsive to that determination. In an embodiment of any of the above, the operating threshold pressure is greater than atmospheric pressure. In an embodiment of any of the above, the operating threshold pressure is substantially greater than atmospheric pressure.

In an embodiment of any of the above, the operating threshold pressure is between 1.2 bar and 13 bar, optionally between 1.5 bar and 8 bar, and optionally between 2.5 bar and 6 bar.

In an embodiment of any of the above, the selectively openable outflow valve is self-actuatable. In an embodiment of any of the above, the selectively openable outflow valve is arranged to enter an open position responsive to a pressure difference across the selectively openable outflow valve exceeding a threshold.

In an embodiment of any of the above, the aerosol provision device comprises an outlet and an airflow path from the pressure chamber to the outlet.

In an embodiment of any of the above, the outflow valve is in the airflow path.

In an embodiment of any of the above, the aerosol provision device comprises a pressure dissipation chamber and/or an expansion valve in the airflow path.

In an embodiment of any of the above, the pressure chamber is configured to be fluidly sealed during heating of the heating zone by the heating arrangement such that a pressure increase is obtained due to heating of the article in the heating zone.

In an embodiment of any of the above, the aerosol provision device comprises a mouthpiece, wherein the outlet is in the mouthpiece.

In an embodiment of any of the above, the pressure chamber comprises the receptacle and an auxiliary chamber.

In an embodiment of any of the above, the auxiliary chamber is fluidly connected with the receptacle.

In an embodiment of any of the above, the auxiliary chamber comprises an expansion vessel.

In an embodiment of any of the above, the expansion vessel is configured to control an operating pressure in the pressure chamber, during use.

In an embodiment of any of the above, the aerosol provision device comprises an opening, wherein the article is insertable into the receptacle through the opening. In an embodiment of any of the above, the aerosol provision device comprises a cover configured to close the opening.

In an embodiment of any of the above, the cover fluidly seals with the receptacle.

In an embodiment of any of the above, the aerosol provision device comprises a locking arrangement configured to lock the cover in a closed position during operation of the heating arrangement.

In an embodiment of any of the above, the device is configured to limit operation of the heating arrangement when the cover is in an open position.

In an embodiment of any of the above, the mouthpiece defines the cover.

In an embodiment of any of the above, the receptacle is configured to fully receive the article.

In an embodiment of any of the above, the aerosol provision device comprises a selectively openable inflow valve arranged to selectively allow aerosol to flow into the pressure chamber.

In an embodiment of any of the above, the selectively openable inflow valve is puff-actuated.

In an embodiment of any of the above, the aerosol provision device is arranged to determine that a pressure in the pressure chamber is below a low threshold pressure and to operate the selectively openable inflow valve responsive to that determination.

In an embodiment of any of the above, the selectively openable inflow valve is configured to open in response to the pressure in the pressure chamber being below a low threshold pressure.

In an embodiment of any of the above, the selectively openable inflow valve is self-actuatable.

In an embodiment of any of the above, the low threshold pressure is below atmospheric pressure. In an embodiment of any of the above, the low threshold pressure is less than 1 bar.

In an embodiment of any of the above, the aerosol provision device comprises a sensor arranged to detect that a user is drawing on the aerosol provision device. In an embodiment of any of the above, the sensor comprises at least one of a pressure sensor and a microphone arranged to detect airflow resulting from a user drawing on the aerosol provision device.

In an embodiment of any of the above, the aerosol provision device comprises a pressure chamber pressuriser arranged to pressurise the pressure chamber.

In an embodiment of any of the above, the pressuriser comprises a piston.

In an embodiment of any of the above, the pressuriser comprises a source of pre-pressurised gas.

In an embodiment of any of the above, the pressuriser comprises the heating arrangement.

In an embodiment of any of the above, the pressuriser is arranged to pressurise aerosol in the pressure chamber to at least 1.2, optionally at least 1.5 bar, and optionally at least 2.5 bar.

In an embodiment of any of the above, the aerosol provision device comprises a pressure relief valve arranged to vent the pressure chamber to atmosphere responsive to pressure within the pressure chamber exceeding 13 bar, optionally exceeding 8 bar, and optionally exceeding 6 bar.

In an embodiment of any of the above, the pressure relief valve is arranged to vent the pressure chamber from a distal end of the aerosol provision device.

In an embodiment of any of the above, the aerosol provision device comprises an indicator arranged to indicate to a user that pressure in the pressure chamber has reached a threshold pressure.

In an embodiment of any of the above, the heating arrangement comprises an inductive heating arrangement.

In an embodiment of any of the above, the heating arrangement comprises a resistive heating arrangement.

In accordance with embodiments described herein, there is provided an aerosol provision system comprising the aerosol provision device of any of the above and an article comprising aerosol-generating material.

In an embodiment of any of the above, the aerosol-generating material is at least one of a solid aerosol-generating material and a gel. In an embodiment of any of the above, the shape of the article is configured to conform with the heating zone.

In accordance with embodiments described herein, there is provided a method of generating an aerosol for inhalation by a user comprising: heating an aerosolgenerating material to generate an aerosol; pressurising the aerosol to generate a pressurised aerosol; inhaling the pressurised aerosol by the user.

In an embodiment of any of the above, the pressurising of the aerosol is caused by the heating of the aerosol-generating material.

In an embodiment of any of the above, the method comprises placing the aerosol-generating material in a pressure chamber and heating the aerosol-generating material within the pressure chamber.

In an embodiment of any of the above, the method comprises selectively releasing aerosol from the pressure chamber.

In an embodiment of any of the above, the selectively releasing aerosol from the pressure chamber is responsive to a determination that a user is drawing on an aerosol provision device comprising the pressure chamber.

In an embodiment of any of the above, the selectively releasing aerosol from the pressure chamber is responsive to a determination that the aerosol has reached a threshold pressure.

In an embodiment of any of the above, the method comprises indicating to a user that the aerosol has reached a threshold pressure.

In an embodiment of any of the above, the operating threshold pressure is greater than atmospheric pressure. In an embodiment of any of the above, the operating threshold pressure is substantially greater than atmospheric pressure.

In an embodiment of any of the above, the threshold pressure is between 1.2 bar and 13 bar, optionally between 1.5 bar and 8 bar, and optionally between 2.5 bar and 6 bar.

In an embodiment of any of the above, the method comprises, in advance of an anticipated use session, at least one of pre-heating the aerosol-generating material and pre-pressurising the aerosol-generating material. In an embodiment of any of the above, the method comprises pre-heating the aerosol-generating material in advance of an anticipated use session.

In an embodiment of any of the above, the method comprises pre-pressurising the aerosol-generating material in advance of an anticipated use session.

In an embodiment of any of the above, the method comprises pressurising the aerosol to a pressure greater than 1.2 bar, optionally greater than 1.5 bar and optionally greater than 2.5 bar.

In an embodiment of any of the above, the method comprises venting the pressurised aerosol to atmosphere responsive to the pressure of the pressurised aerosol exceeding 13 bar, optionally exceeding 8 bar, and optionally exceeding 6 bar.

Brief Description of the Drawings

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

Figure 1 shows a schematic cross-sectional side view of an aerosol provision system comprising an aerosol provision device and an article comprising aerosol generating material.

Detailed Description

As used herein, the term “aerosol-generating material” is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. Aerosol-generating material may include any plant based material, such as tobacco-containing material and may, for example, include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. Aerosol-generating material also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. Aerosol-generating material may for example be in the form of a solid, a liquid, a gel, a wax or the like. Aerosol-generating material may for example also be a combination or a blend of materials. Aerosol-generating material may also be known as “smokable material”. The aerosol-generating material may comprise a binder and an aerosol former. Optionally, an active and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosolgenerating material is substantially free from botanical material. In some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating material may comprise or be an “amorphous solid”. The amorphous solid may be a “monolithic solid”. In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosolgenerating 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 an aerosol-generating film. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet. The aerosol-generating sheet or shredded sheet may be substantially tobacco free.

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

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

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

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

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

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

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

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

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

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

An aerosol generating device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within a heating chamber of the device which is sized to receive the article.

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

Figure 1 shows a schematic cross-sectional view of an aerosol provision system 10 comprising an aerosol provision device 100 for generating aerosol from an aerosol generating material and an article 300 comprising the aerosol generating material. As Figure 1 is a schematic view, components are not shown to scale and their relative sizes may differ. In broad outline, the device 100 may be used to heat a replaceable article 300 comprising aerosol generating material, to generate an aerosol or other inhalable medium which is inhaled by a user of the device 100. The article 300 and the device 100 together form an aerosol provision system 10.

The device 100 comprises a main body 101. The main body 101 comprises a receptacle 105 defining a heating zone 114. A housing 102 surrounds and houses various components of the main body 101. An opening 103 is formed at one end of the main body 101, communicating with the heating zone 114. The article 300 may be inserted through the opening 103 into the heating zone 114 for heating by an aerosol generator 150. In use, the article 300 may be heated by one or more components of the aerosol generator 150. A cover 118 is arranged to selectively seal the opening 103 to form a sealed pressure chamber 134 around the article 300. The cover 118 may be arranged to selectively form a fluid seal on the opening 103 to form the sealed pressure chamber 134. The sealed pressure chamber 134 may be a fluid sealed pressure chamber 134.

The main body 101 may define one or more ends of the device 100. The end of the device 100 closest to the opening 103 may be known as the proximal end (or mouth end) 104 of the device 100 because, in use, it is closest to the mouth of the user. In use, a user inserts the article 300 into the opening 103, operates the aerosol generator 150 to begin heating the aerosol generating material and draws on the aerosol generated in the device. This causes the aerosol to flow through the device 100 along a flow path towards the proximal end of the device 100. The other end of the device furthest away from the aperture 103 may be known as the distal end 106 of the device 100 because, in use, it is the end furthest away from the mouth of the user. As a user draws on the aerosol generated in the device 100, the aerosol flows in a direction towards the proximal end of the device 100. The terms proximal and distal as applied to features of the device 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along the longitudinal axis.

The device 100 also includes a button assembly 200, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the button assembly 200. The button assembly 200 may be assembled as part of the other assemblies of the aerosol provision device 100.

The device 100 comprises an electrical component, such as a connector/port 160, which can receive a cable to charge the device 100. For example, the connector 160 may be a charging port, such as a USB charging port. In some examples the connector 160 may be used additionally or alternatively to transfer data between the device 100 and another device, such as a computing device.

The device 100 comprises a power source 170, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery. The battery is electrically coupled to the aerosol generator 150 to supply electrical power when required and under control of a controller to heat the aerosol generating material.

The device 100 comprises an electronics module 112. The electronics module 112 may comprise, for example, a printed circuit board (PCB). The PCB may support at least one controller, such as a processor, and memory. The PCB may also comprise one or more electrical tracks to electrically connect together various electronic components of the device 100. For example, the battery terminals may be electrically connected to the PCB so that power can be distributed throughout the device 100.

In embodiments, the aerosol generator 150 is an inductive heating assembly and comprises various components to heat the aerosol generating material of the article 300 via an inductive heating process. In other embodiments, any suitable form of aerosol generator 150 may be used, such as one or more of a resistive heater, a radiative heater and a chemical heater. The aerosol generator 150 may comprise an induction-type heating system, including a magnetic field generator 192. The magnetic field generator 192 comprises an inductor coil assembly 194. The aerosol generator 150 comprises a heating element 196. The heating element 196 is also known as a susceptor.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrical ly-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 electrical ly-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.

Induction heating is a process of heating an electrically conducting object (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field.

The inductor coil assembly 194 includes an inductor coil 198. In embodiments, the number of inductor coils differs. In embodiments, a two or more inductor coils are used. The inductor coil assembly 194 also comprises a coil support (not shown). The coil support is tubular.

The heating element 196 is part of a heating arrangement 199. The heating arrangement 199 is arranged to heat the heating zone 114. The heating element 196 of this embodiment is hollow. In embodiments, the heating element 196 defines at least part of a receptacle within which aerosol generating material is received. For example, the article 300 can be inserted into the heating element 196. The heating element 196 is tubular, with a circular cross section. The heating element 196 has a generally constant diameter along its axial length. In embodiments, the heating element 196 may be flat. A plurality of heating elements 196 may be provided. For example, two heating elements 196 may be provided and the receptacle 105 may be disposed between the heating elements 196.

In embodiments, the heating arrangement 199 defines the receptacle 105 and the heating element 196 upstands in the receptacle 105. The heating element 196 may comprise a pin or blade arranged to penetrate the consumable 300. In embodiments, the consumable 300 comprises the heating element 196 and the aerosol provision device 100 comprises an inductor coil arranged to inductively heat the heating element in the consumable.

The heating element 196 is formed from an electrically conducting material suitable for heating by electromagnetic induction. The heating element 196 in the present example is formed from a carbon steel. It will be understood that other suitable materials may be used, for example a ferromagnetic material such as iron, nickel or cobalt.

In other embodiments, the feature acting as the heating element may not be limited to being inductively heated. The feature, acting as a heating element, may therefore be heatable by electrical resistance. The aerosol generator 150 may therefore comprise electrical contacts for electrical connection with the apparatus for electrically activating the heating element by passing a flow of electrical energy through the heating element. The aerosol generator 150 in embodiments is a resistive heater.

The receptacle 105 and article 300 are dimensioned so that the article 300 is received by the heating element 196. This helps ensure that the heating is most efficient. The article 300 of this example comprises aerosol generating material. The aerosol generating material is positioned within the receptacle 105. The article 300 may also comprise other components such as a filter, wrapping materials and/or a cooling structure. The receptacle 105 comprises an opening 116. The opening 116 communicates with the opening 103 of the housing 102. The opening 116 is for receiving the article 300. The article 300 may be inserted into and withdrawn from the receptacle 105 via the opening 116. The article 300 is fully receivable in the receptacle 105. The opening 116 is selectively closable.

The aerosol provision device 100 comprises a cover 118 arranged to selectively close the opening 116. The cover 118 is movable relative to the main body 101. The cover 118 is hinged to the main body 101. In embodiments, the cover 118 may be slidably joined to the main body 101. The cover 118 is arranged to selectively form a fluid seal. The cover 118 is arranged to selectively form an air tight seal. The cover 118 is movable between an open position in which the article 300 may be inserted in the receptacle 105 via the opening 116 and a closed position in which the opening 116 is closed by the cover 118. In the closed position, the cover 118 and the receptacle 105 form a sealed chamber around the article 300.

The aerosol provision device 100 is configured to limit operation of the heating arrangement 199 when the cover 118 is in an open position. The aerosol provision device 100 comprises a detector (not shown) arranged to detect that the cover 118 is in the closed position and/or the open position. The detector may comprise, for example, one or more of a mechanical switch, a magnetic arrangement, an electrical contact or an optical detector. The aerosol provision device 100 is configured to limit operation of the heating arrangement 199 responsive to an output of the detector.

The aerosol provision device 100 comprises a mouthpiece 120. The mouthpiece 120 is arranged to be drawn on by the user to inhale the aerosol. In this embodiment, the mouthpiece 120 is a part of the cover 118. In other embodiments, the mouthpiece 120 and cover 118 may be separate components.

The aerosol provision device comprises an outlet passage 122. The outlet passage 122 is an air flow passage extending from the receptacle 105 to an outlet 124 communicating with the exterior of the aerosol provision device 100. The outlet passage 122 is arranged to permit aerosol to flow from the pressure chamber 134 to the outlet 124. The outlet 124 is provided in the proximal end 104 of the aerosol provision device 100. Aerosol may flow from the receptacle 105 through the outlet passage 122 to the exterior of the aerosol provision device 100 for inhalation by user. The outlet passage 122 extends to the mouthpiece 120. The outlet 124 is defined in the mouthpiece 120.

The aerosol provision device 100 comprises an outflow valve 130. The outflow valve 130 is disposed in the outlet passage 122. The outflow valve 130 is a selectively openable outflow valve. The outflow valve 130 is arranged to selectively allow aerosol to flow through the outlet passage 122. The outflow valve 130 is operable in an open position in which airflow through the outlet passage 122 is permitted and in a closed position in which airflow through the outlet passage 122 is prevented.

In embodiments, the outflow valve 130 is operable in an operating state in which the outflow valve 130 may selectively enter the open position or the closed position. The outflow valve 130 is operable in a non-operating state in which the outflow valve 130 remains in the closed position. In broad overview, the outflow valve 130 is maintained in the non-operating state during heating of the article 300 and enters the operating state when an operating pressure threshold within the pressure chamber 134 is reached. In the operating state, the outflow valve 130 remains in the closed position until a user either draws on the aerosol provision device 100 or provides a user input, such as by operating a button on the aerosol provision device 100. The outflow valve 130 enters the open position responsive either to a user drawing on the aerosol provision device 100 or providing the user input.

In embodiments, the aerosol provision device 100 comprises a puff sensor arranged to detect that a user is drawing on the aerosol provision device 100, such as a microphone or mechanical sensor. The puff sensor is disposed in or adjacent to the outlet passage 122. When the outflow valve 130 is in the operating state, the outflow valve 130 may enter the open position responsive to an output of the puff sensor. The outflow valve 130 may therefore be puff-actuated.

In embodiments, the outflow valve 130 may be arranged to enter the open position responsive to a pressure difference across the outflow valve 130 exceeding a pressure difference threshold, when the outflow valve is in the operating state. The outflow valve 130 may therefore be self-actuated. In such embodiments, the puff sensor may optionally be omitted. The pressure difference threshold is greater than a difference between the operating pressure threshold and atmospheric pressure. This prevents aerosol from passing through the outflow valve 130 before the operating pressure has been attained. The pressure difference threshold is lower than a difference between the operating pressure threshold and a user draw pressure. When the user draws on the aerosol provision device 100, a negative pressure is applied to the outflow valve 130, increasing the pressure difference across the outflow valve 130. A user may therefore cause the pressure difference across the outflow valve 130 to exceed the pressure difference threshold by drawing on the aerosol provision device 100, causing the outflow valve 130 to enter the open position.

The aerosol provision device 100 comprises an inlet passage 126. The inlet passage 126 is an air flow passage extending from an inlet 128 communicating with the exterior of the aerosol provision device 100 to the receptacle 105. The inlet passage 126 is arranged to permit airflow from the exterior of the aerosol provision device 100 to the pressure chamber 134. The inlet 128 is provided in the distal end 106 of the aerosol provision device 100. This reduces the likelihood of the user blocking the inlet 128 with their hand, or another body part or feature.

The aerosol provision device 100 comprises an inflow valve 132. The inflow valve 132 is a selectively openable inflow valve 132 arranged to selectively allow airflow through the inlet passage 126. In embodiments, the inflow valve 132 is puff-actuated. That is, the inflow valve 132 may be actuated in response to a determination that a user is drawing on the aerosol provision device 100. In embodiments, the inflow valve 132 is arranged to permit air flow from the exterior of the aerosol provision device 100 to the pressure chamber 134 and to prevent airflow from the pressure chamber 134 to the exterior of the aerosol provision device 100. In embodiments, the inflow valve 132 is a one-way valve.

The aerosol provision device 100 therefore comprises an airflow path from the inlet 128 to the outlet 124, via the inlet passage 126, the receptacle 105 and the outlet passage 122.

The aerosol provision device 100 comprises a pressure chamber 134. The pressure chamber 134 contains the heating zone 114. The pressure chamber 134 is defined by the receptacle 105 and the cover 118. In embodiments, the pressure chamber 134 may be defined solely by the receptacle 105, or by the receptacle 105 in combination with a part of the article 300. The pressure chamber 134 is configured to be fluidly sealed during heating of the heating zone 114 by the heating arrangement 199 such that a pressure increase is obtained due to heating of the article 300 in the heating zone 114. Pressurised aerosol may therefore be delivered to the user, providing an improved user experience. It has been found that pre-pressurising the aerosol during heating provides an aerosol which may be perceived as smoother by the user.

The aerosol provision device 100 may therefore be arranged to pre-pressurise aerosol in advance of a use session. For example, a user may initiate pre-pressurisation of the aerosol by providing a user input to the aerosol provision device, such as via a button. The aerosol generator 150 may then commence heating the aerosol-generating material to form an aerosol. The aerosol may then be pressurised in the heating chamber until an operating threshold pressure is reached, at which point the user may begin a use session by drawing on the aerosol provision device 100 or providing a further user input to the aerosol provision device 100.

The aerosol provision device 100 comprises a pressure chamber pressuriser 136 arranged to pressurise the pressure chamber 134. In embodiments, the pressuriser 136 is provided by the heating arrangement 199. That is, heating of the article 300 by the heating arrangement 199 is sufficient to cause a pressure increase in the pressure chamber 134. In embodiments, the pressuriser 136 comprises one or more of a piston and a source of pre-pressurised gas.

The pressuriser 136 is arranged to pressurise aerosol in the pressure chamber 134 to greater than atmospheric pressure. The pressuriser 136 is arranged to pressurise aerosol in the pressure chamber 134 to substantially greater than atmospheric pressure. In embodiments, the pressuriser 136 is arranged to pressurise aerosol in the pressure chamber 134 to at least 1.2 bar, optionally at least 1.5 bar, and optionally at least 2.5 bar.

The aerosol provision device 100 is arranged to determine that the aerosol has reached the operating threshold pressure and to permit operation of the outflow valve 130 responsive to that determination. The operating threshold pressure is between 1.2 bar and 13 bar, optionally between 1.5 bar and 8 bar, and optionally between 2.5 bar and 6 bar. The aerosol provision device comprises a pressure sensor 149 arranged to detect the pressure in the pressure chamber 134. In embodiments, the pressure sensor 149 may be omitted. For example, the outflow valve 130 may be actuated based on, including based solely on, a pressure difference across the outflow valve 130.

The aerosol provision device 100 comprises an indicator 148 arranged to indicate to a user that pressure in the pressure chamber 134 has reached the operating threshold pressure. The aerosol provision device 100 is arranged to determine that a pressure in the pressure chamber 134 is below a low threshold pressure and to operate the inflow valve 132 responsive to that determination. The inflow valve 132 is configured to open in response to the pressure in the pressure chamber 134 being below a low threshold pressure. In embodiments, the inflow valve 132 is self-actuatable. The low threshold pressure is below atmospheric pressure.

A method of operating the aerosol provision device may comprise moving the cover 118 to the open position, inserting the article 300 into the receptacle 105, moving the cover 118 to the closed position, and operating the button assembly 200. Responsive to operation of the button assembly 200, the aerosol generator 150 begins to heat the article 300, causing the pressure in the pressure chamber 134 to rise due to the increase in temperature within the sealed volume of the pressure chamber 134. When pressure in the pressure chamber 134 reaches the operating threshold pressure, as detected by the pressure sensor 149, the indicator 148 indicates to the user that they may draw on the aerosol provision device 100 and the outflow valve 130 enters the operating state to allow aerosol to be drawn out of the pressure chamber 134.

The aerosol provision device 100 comprises an auxiliary chamber 138. The auxiliary chamber 138 is fluidly connected with the pressure chamber 134. The auxiliary chamber 138 comprises an expansion vessel 140. The expansion vessel 140 is configured to control an operating pressure in the pressure chamber 138, during use. This ensures that aerosol may be maintained at the operating threshold pressure in the pressure chamber 134, providing a more consistent user experience. The auxiliary chamber 138 may be omitted.

The aerosol provision device 100 comprises an expansion valve 142 in the outlet passage 122. The expansion valve 142 moderates the aerosol pressure for inhalation by the user. In embodiments, the aerosol provision device 100 comprises a pressure dissipation chamber. The pressure dissipation chamber may form part of the outlet passage 122. The pressure dissipation chamber may be omitted.

The aerosol provision device 100 comprises a pressure relief valve 144 arranged to vent the pressure chamber 134 to atmosphere responsive to pressure within the pressure chamber 134 exceeding 13 bar, optionally exceeding 8 bar, and optionally exceeding 6 bar. This reduces the likelihood of damage to the aerosol provision device 100 and/or injury to the user, caused by excessive pressure in the pressure chamber 134. The pressure relief valve 144 is arranged to vent the pressure chamber 134 from the distal end 106 of the aerosol provision device 100. This reduces the likelihood of venting the pressure relief chamber onto or near the user’s hand or face, which may cause injury. In embodiments, the pressure relief valve 144 is arranged to open responsive to an output of a pressure sensor. In embodiments, the pressure relief valve 144 is arranged to open in response to a pressure difference across the pressure relief valve 144 exceeding an excess pressure difference threshold.

The pressure relief valve 144 is provided in a pressure relief passage 146. The pressure relief passage 146 extends from the pressure chamber 134 to the exterior of the aerosol provision device 100. In embodiments, the pressure relief passage 146 extends from the exit airflow passage 122 or the inlet passage 126 to the exterior of the aerosol provision device 100. In embodiments, the pressure relief passage 146 forms part of the inlet airflow passage 126.

In the embodiment of Figure 1, the pressure chamber 134 is partly formed by the receptacle 105. In other embodiments, the pressure chamber 134 may be separate from the receptacle 105. The article 300 may be heated in the receptacle 105 by the aerosol generator 150 to generate an aerosol. The aerosol may then flow from the receptacle 105 into the pressure chamber 134 to be pressurised by the pressuriser before inhalation by the user.

By maintaining a fixed volume within a chamber during heating, the pressure and temperature can increase further, leading to improved heating efficiency.

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

Claims

1. An aerosol provision device for generating an aerosol from aerosol-generating material comprising: a receptacle defining a heating zone for receiving an article comprising aerosol-generating material; a heating arrangement configured to heat the heating zone to generate an aerosol from the aerosol-generating material; and a pressure chamber arranged to pressurise the aerosol.

2. The aerosol provision device of claim 1 , comprising a selectively openable outflow valve arranged to selectively allow aerosol to flow from the pressure chamber.

3. The aerosol provision device of claim 2, wherein the selectively openable outflow valve is puff-actuated.

4. The aerosol provision device of claim 2 or claim 3, wherein the aerosol provision device is arranged to determine that the aerosol has reached an operating threshold pressure and to permit operation of the outflow valve responsive to that determination.

5. The aerosol provision device of any of claims 1 to 4, wherein the pressure chamber is configured to be fluidly sealed during heating of the heating zone by the heating arrangement such that a pressure increase is obtained due to heating of the article in the heating zone.

6. The aerosol provision device of any of claims 1 to 5, wherein the pressure chamber comprises the receptacle and an auxiliary chamber comprising an expansion vessel configured to control an operating pressure in the pressure chamber, during use.

7. The aerosol provision device of any of claims 1 to 6, comprising a selectively openable inflow valve arranged to selectively allow airflow into the pressure chamber.

8. The aerosol provision device of any of claims 1 to 7, wherein the aerosol provision device comprises a sensor arranged to detect that a user is drawing on the aerosol provision device.

9. The aerosol provision device of any of claims 1 to 8, wherein the aerosol provision device comprises a pressure chamber pressuriser arranged to pressurise the pressure chamber.

10. The aerosol provision device of claim 9, wherein the pressuriser comprises at least one of a piston; a source of pre-pressurised gas; and the heating arrangement.

11. The aerosol provision device of any of claims 1 to 10, comprising an indicator arranged to indicate to a user that pressure in the pressure chamber has reached an operating threshold pressure.

12. An aerosol provision system comprising the aerosol provision device of any of claims 1 to 11 and an article comprising aerosol-generating material.

13. The aerosol provision system of claim 12, wherein the aerosol-generating material is at least one of a solid aerosol-generating material and a gel.

14. A method of generating an aerosol for inhalation by a user comprising: heating an aerosol-generating material to generate an aerosol; pressurising the aerosol to generate a pressurised aerosol; inhaling the pressurised aerosol by the user.

15. The method of claim 14, comprising causing a pressurising of the aerosol by heating of the aerosol-generating material.

16. The method of any of claims 14 or 15, comprising selectively releasing aerosol from the pressure chamber.

17. The method of claim 16, comprising selectively releasing aerosol from the pressure chamber in response to a determination that a user is drawing on an aerosol provision device comprising the pressure chamber.

18. The method of claim 16 or 17, comprising selectively releasing aerosol from the pressure chamber in response to a determination that the aerosol has reached an operating threshold pressure.

19. The method of any of claims 14 to 18, comprising indicating to a user that the aerosol has reached an operating threshold pressure.

20. The method of any of claims 14 to 19, comprising, in advance of an anticipated use session, at least one of pre-heating the aerosol-generating material and pre-pressurising the aerosol-generating material.