A NON-COMBUSTIBLE AEROSOL PROVISION DEVICE

A non-combustible aerosol provision device, the device being configured to generate an aerosol by heating a consumable, the device including means to engage a component of the consumable when the consumable is inserted into the device, so that, when a portion of the consumable is removed from the device, the component is retained by said means to separate the component from the portion of the consumable.

TECHNICAL FIELD

The present invention relates to a non-combustible aerosol provision device.

BACKGROUND

There is a drive toward increasing the recyclability and sustainability of consumer products to reduce harm to the environment. Manufacturers and suppliers may also benefit from recycling as manufacturing costs can be reduced by reusing recycled components.

There is often a difficulty in engaging consumers with recycling, particularly where the act of recycling imposes an additional burden on them, such as sorting their waste into different recyclable categories.

SUMMARY

In accordance with some embodiments described herein, in a first aspect there is provided a non-combustible aerosol provision device, the device being configured to generate an aerosol by heating a consumable, the device comprising means to engage a component of the consumable when the consumable is inserted into the device, so that, when a portion of the consumable is removed from the device, the component is retained by said means to separate the component from the portion of the consumable.

DETAILED DESCRIPTION

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 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 non-combustible aerosol provision device and a consumable for use with the non-combustible 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 device 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 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.

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

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,cannabisor another botanical.

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

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected fromeucalyptus, star anise, cocoa and hemp.

In some embodiments, 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.

In some embodiments, the substance to be delivered comprises a flavor.

In some embodiments, the flavor comprises menthol, spearmint and/or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted fromcannabis.

An 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 semi-solid (such as a gel) which may or may not contain an active substance and/or flavorants.

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 aerosol-generating material is substantially free from botanical material. In particular, 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 aerosol-generating material may, for example, comprise from about 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % of amorphous solid.

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

The aerosol-generating material may comprise one or more active substances and/or flavors, one or more aerosol-former materials, and optionally one or more other functional material.

The one or more other functional materials may comprise one or more of pH regulators, coloring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

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 aerosol-generating 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, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

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, flavor, 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 aerosol-modifying agent may, for example, comprise one or more of a flavorant, a colorant, 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 aerosol-modifying 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. In some embodiments, 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. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components.

A non-combustible aerosol provision device20(herein referred to simply as the ‘device20’) is shown schematically inFIG.1. The device20comprises a wall21that defines a rod shaped consumable receiving space22(herein referred to simply as ‘receiving space22’); and a heater23configured to heat the consumable receiving space22.

The device further comprises a power source24and a control unit25which are configured to power and control the heater23, respectively. The power source24may be, for example, a battery24, 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 various components of the device, including the heater23, receiving space22, battery24and control unit25are retained within a housing26.

The device20is of the approximate size and shape to allow a user to hold the device20in a single hand. In use, a consumable1comprising an aerosol generating material5is inserted into the receiving space22and heated by the heater23. The heat causes one or more volatiles from the aerosol-generating material5to form an aerosol. A mouth end12of the consumable protrudes from the device as illustrated byFIG.2. To inhale the aerosol generated by the heated consumable1, a user draws on the mouth end12of the consumable1, in the manner of a conventional cigarette.

The device further comprises an inlet27as shown inFIG.1. When a user draws on the consumable1, air is drawn from the inlet27and through the consumable.

The device20further comprises a first activation button28to allow a user to turn the device20on or off, and a second activation button29to activate the heater23. To use the device20, a user draws on the mouth end12of the consumable1while simultaneously pressing the second activation button29to cause the heater23to heat the consumable1and generate an aerosol.

The inlet27may comprise a pressure sensor (not shown) which acts as a ‘puff sensor’. The puff sensor is configured to detect a drop in pressure at the air inlet27which indicates that a user is drawing on a consumable1located within the receiving space22. The device20is thereby configured to activate the heater23in response to a drop in pressure detected at the air inlet27.

The control unit25is configured to direct electrical energy from the battery24to activate the heater23in response to an input signal.

In one example, the input signal is generated when the second activation button29is pressed by the user. In another embodiment, the input signal is generated when a pressure drop is detected at the inlet27by a pressure sensor.

The heater23may be an inductive heating assembly23and comprise various components to heat the consumable receiving space via an inductive heating process. 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. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive heater and the susceptor, allowing for enhanced freedom in construction and application.

In the example illustrated byFIG.1, the inductive heating assembly comprises an inductor coil201. The inductor coil201is made from an electrically conducting material. For example, the inductor coil201may be made from Litz wire/cable which is wound in a helical fashion about the wall21. Litz wire comprises a plurality of individual wires which are individually insulated and are twisted together to form a single wire. Litz wires are designed to reduce the skin effect losses in a conductor. The inductor coil201is made from copper Litz wire which has a rectangular cross section. In other examples the Litz wire can have other shape cross sections, such as circular. The inductor coil201is configured to generate a varying magnetic field for heating a susceptor.

FIG.3shows an article1that, in some embodiments, form part of a non-combustible aerosol provision system comprising the article1and the non-combustible aerosol provision device20. The article1is rod shaped and comprises a mouth end12and a distal end12′, opposite the mouth end12.

The article1comprises an aerosol generating section2circumscribed by a wrapper3. In the illustrated embodiment, a heating element4extends axially within the aerosol generating section2. The heating element4is a susceptor comprising a material configured for heating by induction.

Therefore, when the article1is inserted into the non-combustible aerosol provision device20, the heating element4is inductively heated by the heater23of the device20to heat the aerosol generating section2. Heat from the heating element4is transferred from the heating element4to aerosol generating material5of the aerosol generating section2to generate an aerosol for inhalation by a user.

The article ofFIG.1further comprises a filter plug6arranged in coaxial alignment with the aerosol generating section2and attached thereto by a paper wrapper8that circumscribes the length of the article1. The filter plug6may additionally be wrapped in a plug wrap7disposed in between the filter plug6and the paper wrapper8. Such articles1are typically discarded following use. There is an environmental benefit if consumer participation of recycling can be encouraged.

The heating element4may be made from any material suitable for induction heating. In the present example, the heating element is made from a ferrous material, such as steel. Such materials must be separated from the aerosol generating section2for recycling.

Referring again toFIG.1, the device20comprises means202to engage a component of the consumable1when the consumable1is inserted into the device20, so that, when a portion of the consumable1is removed from the device20, the component is retained by said means202to separate the component from the portion of the consumable1. In particular, the device20comprises means202to engage the heating element4of the consumable1when the consumable1is inserted into the receiving space22. Said means202are configured to retain the heating element4in the device20when a portion of the consumable1is removed from the device20.

Therefore, the heating element4is separated from the portion of the consumable1for recycling. It will be appreciated that ‘portion of the consumable1’ herein means that part of the consumable that is not retained by said means.

The means202are configured to engage a portion of the heating element at the distal end12′ of the consumable1.FIGS.4and5are a detailed schematic illustration showing part of the receiving space23, the means202to engage the heating element4and a disposal chamber203. In the illustrated embodiments, the means202comprise an engaging portion204that upstand from a base205of the receiving space22.

The engaging portion204illustrated byFIG.4is configured for embodiments in which the heating element4comprises a magnetic material. The engaging portion204comprises a tine206that penetrates an axial end of the consumable1when the consumable is inserted into the receiving space22. The tine206is disposed to locate adjacent the heating element4. The engaging portion204comprises an electromagnet207that, when activated, magnetises the tine206and attracts the heating element4. The electromagnet207comprises a coil208that is connected to the power source24. The coil208is provided at a lower end of the tine206. That is, an end of the tine206that is not configured for insertion into the consumable1. When a current is provided to the coil208the tine206is magnetised to draw a heating element in proximity to the tine206toward the tine206.

The engaging portion illustrated byFIG.5comprises a pair of tines209that penetrate an axial end of the consumable1when the consumable1is inserted into the receiving space22. The pair of tines209are positioned within the receiving space22so that the tines209locate either side a portion of the heating element4. The engaging portion204comprises an actuator210to effect movement of the tines209toward each other. When a current is provided to the actuator210, the tines209move toward each other, trapping the heating element4between the tines209. In the illustrated embodiment, the tines209further comprise a barb211provided on one of the tines209to engage the heating element4. The bard extends in a direction of movement of the tine209. The barb211may be configured to penetrate the heating element4, or to engage an aperture in the heating element4.

A consumable sensor212is provided that relays the presence of a consumable to the control unit25when the consumable1is inserted into the receiving space22. The control unit25may distribute power to the engaging portion204following receipt of a signal from the consumable sensor212indicating the presence of a consumable1. Therefore, the engaging portion204is activated on insertion of the consumable1. When a user removes the consumable1, the consumable sensor212ceases to relay the presence of the consumable1to the control unit25.

The control unit25is configured to deactivate the engaging portion204only after a predetermined period of time from the end of the signal indicating the presence of the consumable1. This allows a user to completely remove a portion of the consumable1while the engaging portion204remains active. Therefore, the heating element4remains attached to the engaging portion204as the portion of the consumable1is removed.

In the particular embodiment ofFIG.4, the consumable sensor212relays the presence of the consumable1to the control unit25, which then distributes power to the electromagnet207.

Therefore, the electromagnet207is activated on insertion of the consumable1. When a user removes a portion of the consumable1, the consumable sensor212ceases to relay the presence of the portion of the consumable1to the control unit25. The control unit25is configured to deactivate the electromagnet207only after a predetermined period of time from the end of the signal indicating the presence of the portion of the consumable1. This allows a user to completely remove the portion of the consumable1while the electromagnet207remains active. Therefore, the heating element4remains attached to the tine206due to the electromagnetic force induced by the electromagnet207as the portion of the consumable1is removed.

In the particular embodiment ofFIG.5, the consumable sensor212relays the presence of the consumable1to the control unit25which then distributes power to the actuator210. Therefore, the tines209are moved toward each other on insertion of the consumable1to grip the heating element4. When a user removes a portion of the consumable1, the consumable sensor212ceases to relay the presence of the portion of the consumable1to the control unit25. The control unit25is configured to activate the actuator210to move the tines apart, releasing their grip on the heating element4, only after a predetermined period of time from the end of the signal indicating the presence of the portion of the consumable1. This allows a user to completely remove the portion of the consumable1while the heating element4is retained by the tines209.

The disposal chamber203is provided for used heating elements4. By ‘used heating elements4’ it is meant heating elements4that have been removed from the portion of the consumable1by means202and retained within the device20. The disposal chamber203is disposed below the receiving space22. That is to say, the disposal chamber203is disposed below the receiving space22when the device20is oriented as shown inFIG.2, with the consumable1protruding from an upmost face of the device20. Therefore, when the engaging portion204is deactivated, the heating element4may fall through into the disposal chamber203under gravity. The disposal chamber203collects heating elements4as consumables1pass through the device20. Although not shown, the disposal chamber203may comprise a tray that can be removed to allow emptying of the disposal chamber203. For example, a portion of the disposal chamber203may be removable from the device20, said portion comprising the tray and being configured for holding the used heating elements4.

A trap door213is provided to selectively open or close the disposal chamber203. When the trap door213is open, the receiving space22communicates with the disposal chamber203. When the trap door213is closed, the receiving space22is closed off form the disposal chamber203. The trap door213is electronically actuated. In one embodiment, the control unit25distributes power to the trap door213to selectively open or close the trap door213. The control unit25may send a signal to the trap door213to open the trap door213following a predetermined period from when the consumable sensor212ceases to relay the presence of the consumable1to the control unit25. Therefore, the trapdoor213is opened only after the consumable1has been removed. Preferably, the trap door213is opened at the same time that the engaging portion204is deactivated so that the heating element4is released by the engaging portion204to drop the heating element4into the disposal chamber203. The control unit25may be configured to close the trap door213on receipt of a signal from the consumable sensor212indicating the presence of a consumable1.

In another embodiment illustrated byFIG.6, in which like features retain the same reference numbers, the heating element4extends beyond an axial end of the consumable1to protrude from the consumable1. In such an embodiment, it is not a requirement that the engaging portion204penetrates the axial end of the consumable1. Instead, the receiving space22may be configured so that the axial end of the consumable is supported spaced from the base205of the receiving space22. This may be achieved, for example, by a narrowing of the receiving space22near the base205, or by a ledge (not shown) extending into the receiving space to support the axial end of the consumable1. In such examples, the an extended part9of the heating element4makes contact with the engaging portion204without the consumable1being pushed all the way to the base of the receiving space22. This may be useful, for example, where the axial end of the consumable1is less suitable for penetration by the engaging portion204. In the example, ofFIG.6, the axial end of the consumable1is provided with a distal end plug14. The distal end plug14will be less easily penetrated than a distal end of aerosol generating material5. The distal end plug14is provided to prevent condensate from seeping out of the distal end12′ of the article1and into the receiving space22of the aerosol provision device20during use. The distal end plug14is provided with its own plug wrap15and is adjoined to a distal end12′ of the aerosol generating section2by the paper wrapper3. The heating element4extends through the distal end plug14and out of the distal end12′ of the article1, terminating at the extended portion9. The paper wrapper3is adhered to the plug wrap15to ensure the distal end plug14remains in place throughout use of the article1, including during removal of the heating element4.

The consumable1may be provided with any additional segments required. The example ofFIG.6shows a cooling segment10and an expansion segment11arranged in coaxial alignment with the aerosol generating section2and filter plug7and attached thereto by a series of overlapping wrapping materials. The cooling segment10and the expansion segment11are disposed between the aerosol generating section2and the filter plug7. The cooling segment10is directly adjacent the aerosol generating section2. The expansion segment11is disposed between the cooling segment10and the filter plug7and is directly adjacent to both. A wrapping material13extends over both segments10,11and is disposed in between the segments10,11and the paper wrapper8.

The aerosol generating material5of the aerosol generating section2may comprise a solid aerosol-forming substrate, the solid aerosol-forming substrate may comprise one or more of: powder, granules, pellets, shreds, spaghetti strands, strips or sheets containing one or more of: herb leaf, tobacco leaf, fragments of tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco. The solid aerosol-forming substrate may be in loose form. The aerosol-forming substrate may comprise a plug of solid aerosol-forming substrate.

In the embodiments illustrated byFIGS.3and6, the aerosol generating material5comprises one or more sheets of homogenized tobacco material that has been gathered into a rod, circumscribed by the wrapper3, and cut to provide the aerosol generating section2. Preferably, the homogenized tobacco material comprises a crimped and gathered sheet of homogenized tobacco material. Preferably, folds formed in the crimped and gathered sheet extend in an axial direction through the aerosol generating section2. Therefore, the crimped and gathered sheet of homogenized tobacco material does not obstruct axial movement of the heating element4when it is removed. The homogenized tobacco material may comprise at least one of fibers, binder and aerosol former.

Preferably, the sheet of homogenized tobacco material is a cast leaf. Cast leaf is a form of reconstituted tobacco that is formed from a slurry including tobacco particles, fiber particles, aerosol former, and binder. The cast leaf may additionally comprise one or more flavors.

In the embodiments illustrated byFIGS.3and6, it is therefore preferable that the heating element4comprises a smooth outer surface so as to slide from the aerosol generating section2without catching on aerosol generating material5of the aerosol generating section2. The heating element4may be a cuboid, a rod or any other suitable shape. In some embodiments the heating element4may comprise a flat profile. By ‘flat profile’ it is meant that the heating element4is a cuboid having a thickness significantly smaller than a width or length of the heating element4. Therefore, the heating element4resembles a thin, flat strip.

FIGS.7to9illustrate alternative embodiments of an aerosol provision system comprising a non-combustible aerosol provision device30and a consumable50for use with the device.

FIG.7is a cross-sectional view through a schematic representation of the aerosol provision device30.FIGS.8and9show the consumable40for use in the device30. The aerosol provision device30comprises an outer housing31, a power source32, control circuitry33, a plurality of aerosol generating components34, a receptacle or aerosol forming chamber35, a mouthpiece end36, an air inlet37, an air outlet38, an activation button39and an inhalation sensor40. The outer housing31is arranged such that the power source32, control circuitry33, aerosol generating components34, receptacle35and inhalation sensor40are located within the outer housing31. The outer housing31also defines the air inlet37and air outlet38, described in more detail below. The activation button29is located on the exterior of the outer housing31.

The power source32is configured to provide operating power to the aerosol provision device30. The power source32may be any suitable power source, such as a battery. For example, the power source32may comprise a rechargeable battery, such as a lithium ion battery. The control circuitry33is suitably configured or programmed to control the operation of the aerosol provision device30and distribute power from the power source32to other components of the device30.

FIGS.8and9illustrate the consumable50. The consumable50(also herein referred to as article50) comprises a carrier material51, a heating element52and aerosol generating material53disposed on the heating element52. In the present example, the carrier material51is made of card and is the main structural component of the article50, providing the article50with sufficient rigidity to maintain its shape in normal handling, such as inserting and removing the article50from the aerosol provision device30. The carrier material51is broadly cuboidal in shape and comprises a substantially flat profile. By ‘flat profile’ it is meant that the thickness of the carrier material51is less than its width and length. By way of a concrete example, the length of the carrier material51may be 30 to 80 mm, the width may be 7 to 25 mm, and the thickness may be between 0.2 to 1 mm. However, it should be appreciated that the above are exemplary dimensions of the carrier material51, and in other implementations the carrier material51may have different dimensions as appropriate.

The heating element52is adhered to the carrier material51. The heating element52comprises a thin strip of material that is suitable for inductive heating. In the illustrated embodiments, the heating element52has substantially the same length and width as the carrier material51so that the heating element52can be superimposed on top of the carrier material51and adhered thereto.

FIG.9shows a cross section through the article50. An adhesive layer54is provided between the heating element52and carrier material51to adhere the heating element52and the carrier material51to each other. Part of the heating element52is not adhered to the carrier material51, thereby providing a tab55of the heating element52that is free for a user to lift away from the carrier material51. Therefore a user can peel back the heating element52from the carrier material51, separating the heating element52from the carrier material51for recycling. In the illustrated embodiment, a region between the carrier material51and heating element52is free of adhesive to provide the tab55. However, it will be appreciated that in other embodiments the carrier material51and the heating element52may be adhered to each other over the entire area of overlap between the carrier material51and heating element52. In such embodiments, the tab55may instead be provided by extension of the heating element52beyond the carrier material51. The adhesive used in the adhesive layer54is selected so as to have a bond strength that prevents separation of the heating element52from the carrier material51during insertion and removal of the article50from the device30, but is weak enough to enable a user of normal dexterity to peel the heating element52away from the carrier material51when required.

A plurality of discreet portions of the aerosol generating material53are provided directly on the heating element52. Although three circular portions of aerosol generating material53are provided, it will be appreciated that any number may be provided as required. For example, in another implementation, a two by three array of discreet portions of aerosol generating material53are provided. Importantly, the number and spacing of aerosol generating portions53matches the number and spacing of aerosol generating components34in the device30so that, when the article50is correctly installed in the receptacle35, the aerosol generating portions53are disposed directly above the aerosol generating components34.

Although not shown inFIG.7, the device30may comprise a lid portion and a base portion which are configured to engage with one another to secure an article50within the receptacle35. Various configurations for the lid and base portions are considered, for example, although not shown inFIG.7, the device30may comprise a hinged door or removable part of the outer housing31to permit access to the receptacle35such that a user may insert and/or remove the article50from the receptacle35. The hinged door or removable part of the outer housing31may also act to retain the article50within the receptacle35when closed.

In the described implementation, the aerosol generating material53comprises a gelling agent (sometimes referred to as a binder) and an aerosol former material (which might comprise glycerol, for example). Optionally, the aerosol generating material may comprise one or more of the following: an active substance (which may include a tobacco extract), a flavorant, an acid, and a filler. Other components may also be present as desired.

In the described implementation, the aerosol generating components34are inductive heaters configured to generate a varying magnetic field to induce eddy currents in the heating element52immediately below the discreet portions of aerosol generating material53.

The device30further comprises means202to engage a component of the consumable50when the consumable50is inserted into the device30, so that, when a portion of the consumable50is removed from the device30, the component is retained by said means202to separate the component from the portion of the consumable50. In particular, the device30comprises means202to engage the carrier material51of the consumable50when the consumable50is inserted into the receptacle35of the device30. Said means202are configured to retain the carrier material51in the device30when the portion of the consumable50is removed from the device30. Therefore, the carrier material51is separated from the portion of the consumable50for separate disposal.

In the illustrated implementation, said means202comprise suction cups41. The suction cups41are disc shaped resilient diaphragms that are configured to generate a partial vacuum between a planar lower surface of the carrier material51and the diaphragm when activated, as will be described further below.

To use the device30, an article50is inserted into the receptacle35and the device30is switched on by way of a sensor (not shown) determining that the article50is present in the receptacle35. Alternatively, the device30may be switched on by user interaction with the activation button39. In either event, a signal is sent to the control circuitry33to indicate the presence of the article50.

The control circuitry then distributes power to an actuator42of the suction cups41. The actuator displaces the diaphragm of each suction cup41from a flat state to a conical state, thereby generating a partial vacuum between the diaphragms and the lower surface of the carrier material51to fixedly hold the article50within the receptacle35.

With the article50installed in the receptacle35, a user may then draw on the mouth end36of the device30. When the user draws on the mouth end36of the device30, a flow of air is induced through the inlet37, into the receptacle35and out through the outlet38for inhalation. The inhalation sensor40determines a pressure drop at the inlet37and generates a signal which is transmitted to the control circuitry33. In turn, the control circuitry33distributes power from the power source32to the aerosol generating components34which heat the heating element52as described. Heat from the heating element52vaporizes volatile elements of the discreet portions of aerosol generating material53which are entrained into the flow of air through the device30for inhalation. The control circuitry33may be configured to distribute power to all of the aerosol generating components34at once or, more preferably, in sequence. Therefore, each portion of aerosol generating material53is heated at a different time. Preferably, each portion of aerosol generating material53is heated for a predetermined time, or for a predetermined number of puffs, before the adjacent portion of aerosol generating material53is heated. Once each portion of aerosol generating material53has been heated for predetermined time, or predetermined number of puffs, the device indicates to the user that the article50is due to be replaced. This may be determined, for example, by the control circuitry33. The control circuitry33sends a signal to an end of use indicator43to indicate to the user that the article50is to be removed. The end of use indicator43may be a light or any other suitable indication device. The suction cups41remain in the conical state to retain the carrier material in the receptacle35as the user removes a portion of the article50. In particular, the user lifts and grips the tab55to peel the back the heating element52from the carrier material51. The heating element52is therefore separated from the carrier material51for separate recycling. After a further predetermined period, the control circuitry33distributes power to the actuator42of the suction cups41. The actuator displaces the diaphragm of each suction cup41from the conical state to the flat state, thereby releasing the partial vacuum between the diaphragms and the lower surface of the carrier material51, allowing the carrier material51to be removed from the receptacle35. The device is further provided with a second indicator44to indicate to a user that the carrier material51is no longer retained by the suction cups41. In other words, after the further predetermined period, the control circuitry33sends a signal to the second indicator44to indicate to a user that the carrier material51may be removed from receptacle35for separate disposal.

While the illustrated implementation of said means202comprises suction cups41, it will be appreciated that the device30may be configured to engage the carrier material51in any other suitable way. For example, in another implementation, the carrier material51extends beyond the heating element52to provide a portion56of the carrier material51for clamping. An article50according to this implementation is illustrated byFIG.10, with like features retaining the same reference numbers. In such an implementation, said means202comprises a clamp to clamp the extended portion of the carrier material51. The clamp is electronically actuated. As above, when an article50is inserted into the device30, a signal is sent to the control circuitry33to indicate the presence of the article50. The control circuitry33is configured to distribute power to the clamp to clamp the extended portion of the carrier material51on receipt of said signal. When the article50is due to be replaced, the carrier material51remains clamped to retain the carrier material51in the receptacle35as the user removes a portion of the article50. In particular, the user lifts and grips the tab55to peel the back the heating element52from the carrier material51. The heating element52is therefore separated from the carrier material51for separate recycling. After a period, the control circuitry33distributes power to the clamp to unclamp the carrier material51, allowing the carrier material51to be removed from the receptacle35. The control circuitry33then sends a signal to the second indicator44to indicate to a user that the carrier material51may be removed from receptacle35for separate disposal.