Patent Publication Number: US-2022211104-A1

Title: An Aerosol Generating Device

Description:
TECHNICAL FIELD 
     The present disclosure relates to an aerosol generating device and an aerosol generating system comprising the aerosol generating device and a consumable. 
     TECHNICAL BACKGROUND 
     Aerosol generating devices such as electronic cigarettes are relatively well known and are becoming increasingly popular with consumers in recent years. A common operating principle for such electronic cigarettes is to heat a consumable without burning it to provide an aerosol (also referred to as a vapour) to a user for inhalation. Examples of such consumables include charges of tobacco material or capsules of liquid containing flavourants and active ingredients such as nicotine. 
     Aerosol generating devices often comprise a heater, a power source for supplying electricity to the heater and a receptacle, such as a heating chamber, for receiving the consumable in the vicinity of the heater such that the consumable may be heated to produce the vapour for inhalation. 
     In recent years the popularity of multiple use aerosol generating devices has surpassed that of single use devices which are disposed of after use. In multiple use devices the consumable must be replaced as the consumable can only provide the required active ingredients or flavourants for a limited duration of heating before these components are depleted. This is generally achieved by removing the depleted consumable from the heating chamber and replacing it with a new consumable. 
     There are however several shortcomings with such aerosol generating devices and systems. In particular, the replacement of the consumable is often an awkward process for the user, given the size of the components and the requirement to manoeuvre the aerosol generating device into the appropriate orientation while removing the spent consumable and replacing with a new consumable. This process has to be carried out regularly which exacerbates the problem. Furthermore, the arrangement of the consumable and heating chamber in conventional aerosol generating systems leads to many users finding the systems cumbersome to operate and hold during use. More specifically, many conventional aerosol generating systems require users to position their arm, wrist and hand in an awkward or uncomfortable manner while the system is operated and the user is inhaling a vapour. 
     Therefore, there is need to provide an aerosol generating device and system which addresses one or more of these issues. 
     SUMMARY OF THE INVENTION 
     According to a first aspect of the present disclosure, there is provided an aerosol generating device comprising a heating chamber and a grip; wherein the heating chamber comprises an internal surface extending in a first direction; and wherein the grip is arranged parallel to a longitudinal axis of the device; such that the angle between the first direction and the longitudinal axis of the device is between 5° and 45°. 
     By providing an aerosol generating device with a heating chamber and a grip arranged in this manner, the device is able to be held in a more comfortable and natural position for the user, particularly during operation and inhalation, in terms of the angular relationship between holding the device and a mouthpiece of a consumable in the mouth of the user. This leads to an enhanced smoking experience and allows for an easier consumable replacement process. 
     The grip of the aerosol generating device may have a perimeter which is between 30 mm and 160 mm. This provides a means for the user to hold the aerosol generating device comfortably and securely irrespective of whether the device is in use. 
     Preferably, the aerosol generating device further comprises an air inlet passing from the exterior of the device into the heating chamber, the air inlet being located away from the grip. In this way, the air inlet allows air to enter the heating chamber while ensuring that the inlet is not covered by the user when holding the grip or using the device. 
     The heating chamber of the aerosol generating device may further comprise a bevelled opening. This provides a simple and easy means of inserting a consumable into the heating chamber. Furthermore, the bevelled opening reduces the likelihood of the consumable being damaged during insertion. 
     In some examples of the invention the aerosol generating device further comprises a heating element; wherein the heating element is a heater surrounding the heating chamber. In some further examples of the invention the heater is a film resistive heater. 
     In other examples of the invention the aerosol generating device further comprises a heating element; wherein the heating element is an electromagnetic inductor surrounding or positioned next to the heating chamber. 
     The heating element provides the device with a means of transferring heat to the consumable such that the consumable is heated and vapour is produced for inhalation. The heating element being positioned next to or surrounding the heating chamber allows for heating a large proportion of the consumable, facilitating a uniform constant heating and thus aiding in maintaining a controlled temperature in the heating chamber. In an example of the invention where the heating element is an electromagnetic inductor, surrounding or being positioned next to the heating chamber provides the generation of an efficient electromagnetic field through the heating chamber. 
     Preferably, the aerosol generating device further comprises a battery arranged parallel to the longitudinal axis of the device. The battery provides a power source for components of the device and arranging it in this manner lowers the risk of the battery being damaged by heat from the heating element and other components of the device. 
     Preferably, the aerosol generating device further comprises a printed circuit board (PCB) arranged parallel to the longitudinal axis of the device. Arranging the PCB in this manner reduces the risk of the PCB, or any connected components, being damaged by heat from the heating element and other components of the device. 
     As the first direction is angularly offset from the longitudinal axis of the device, the internal space of the device may be utilised more flexibly, for example with regards to component layout and distribution. 
     The aerosol generating device may further comprise a thermal insulator disposed around the heating chamber and/or between the heating element and the battery and/or the PCB. The incorporation of a thermal insulator disposed in the above described manner shields components of the device from heat. The thermal insulator may also improve the heating efficiency of the device due to less heat being transferred away from the heating chamber. 
     The aerosol generating device may have an elongate cross section in the plane perpendicular to the longitudinal axis of the device. This allows the device to be held comfortably and securely by the user. Preferably, this elongate cross section has a minimum width in the range of 15 mm and 25 mm and a maximum width in the range of 25 mm and 50 mm. 
     In another aspect of the invention there is provided an aerosol generating system comprising an aerosol generating device according to the first aspect of the invention and a consumable; wherein the consumable comprises a mouthpiece and a vapour generating substance; and wherein the heating chamber is arranged to receive the consumable in the first direction in use. The aerosol generating device has the essential features described in claim  1  and optionally any combination of the features described above. The mouthpiece being comprised in the consumable prevents the device becoming contaminated by the build-up of unwanted particulates and bacteria after repeated use. This also prevents undesired mixing of flavours from different types of vapour generating substances. The mouthpiece of the consumable further provides a means for the user to insert or remove the consumable from the system without contacting the vapour generating substance. 
     The consumable may be a straight stick or rod to facilitate easy insertion into the bevelled opening and/or heating chamber of the device as well as to facilitate removal from the device. 
     Preferably, the vapour generating substance of the consumable is solid or semi-solid. This reduces the risk of the vapour generating substance leaking and the user undesirably coming into contact with the vapour generating substance. Example types of solid vapour generating substances include powder, granules, pellets, shreds, strands, porous materials, foam or sheets. 
     In an aspect of the invention where the heating element is an electromagnetic inductor, the consumable may further comprise a susceptor. The susceptor absorbs electromagnetic energy from the electromagnetic inductor and converts the absorbed energy to heat. 
     The vapour generating substance may be any suitable substance capable of generating a vapour. The vapour generating substance may comprise plant derived material and in particular, the substance may comprise tobacco. 
     Preferably, the vapour generating substance may comprise an aerosol-former. Examples of aerosol-formers include polyhydric alcohols and mixtures thereof such as glycerine or propylene glycol. Typically, the vapour generating substance may comprise an aerosol-former content of between approximately 5% and approximately 50% on a dry weight basis. Preferably, the vapour generating substance may comprise an aerosol-former content of approximately 15% on a dry weight basis. 
     In the case of the aerosol generating device comprising an electromagnetic inductor the consumable may further comprise susceptor material such that the electromagnetic inductor heats the susceptor material in use. The susceptor material may comprise one or more, but not limited, of aluminium, iron, nickel, stainless steel and alloys thereof, e.g. nickel chromium. 
     In yet another aspect of the invention, there is provided a smoking device comprising a heating chamber and a PCB or battery; wherein the heating chamber comprises an internal surface extending in a first direction and is configured to accept a vapour generating substance, and wherein the PCB or battery is configured to extend along a second direction; wherein the angle between the first direction and the second direction is between 5° and 45°. 
     The aerosol generating device may comprise a user interface positioned away from the grip. The user interface may provide a means for the user to control the device and may additionally display information about the aerosol generating device or system such as heating chamber temperature or remaining consumable usage or battery power. 
     The aerosol generating device may have a substantially circular cross section in the plane perpendicular to the longitudinal axis of the device. Preferably, the substantially circular cross section has a diameter in the range of 10 mm and 35 mm. The substantially circular cross section may have bevelled edges such that it has the form of a circle with one or more circular segments removed. 
     The aerosol generating device may have a substantially ovoid cross section in the plane perpendicular to the longitudinal axis of the device. Preferably, the substantially ovoid cross section has a minimum diameter in the range of 15 mm and 25 mm and a maximum diameter in the range of 25 mm and 50 mm. The substantially ovoid cross section may have bevelled edges such that it has the form of an oval with one or more elliptical segments removed. 
     The consumable of the aerosol generating system may be crooked shaped such that the angle between the longitudinal axis of the device and the longitudinal axis of the mouthpiece is greater than the angle between the first direction and the longitudinal axis of the device. A consumable with a crooked shape provides further possibilities of system orientation during operation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic illustration of an aerosol generating system according to the present invention where the consumable and aerosol generating system are not coupled. 
         FIG. 2  is a schematic illustration of a close up view of the heating chamber and surrounding region of an aerosol generating device. 
         FIG. 3A  shows an example of the aerosol generating system when the aerosol generating device has an elongate cross section in the plane perpendicular to the longitudinal axis of the device. 
         FIG. 3B  shows the elongate cross section of the device of  FIG. 3A . 
         FIG. 4A  shows an example of the aerosol generating system when the aerosol generating device has a substantially circular cross section in the plane perpendicular to the longitudinal axis of the device 
         FIG. 4B  shows the substantially circular cross section of the device of  FIG. 4A . 
         FIG. 5A  shows an example of the aerosol generating system when the aerosol generating device has a substantially ovoid cross section in the plane perpendicular to the longitudinal axis of the device 
         FIG. 5B  shows the substantially ovoid cross section of the device of  FIG. 5A . 
     
    
    
     DETAILED DESCRIPTION 
     Examples of the present disclosure will now be described by way of example only and with reference to the accompanying drawings. 
       FIG. 1  shows an example of an aerosol generating system comprising an aerosol generating device  100  and a consumable  200  which has not been introduced to the device  100 . The device  100  has an elongate body  101  with areas of the body  101  acting as a grip  120  for holding the device  100 . There is a heating chamber  110  disposed at a first end of the body  101  and arranged to receive the consumable  200  and heat the consumable  200  to generate an inhalable vapour. The device  100  includes a heating element  112  surrounding the heating chamber  110  and a thermal insulator  113  surrounding the heating element  112 . The device further comprises a printed circuit board (PCB)  140  and a battery  130  used to power the device  100  and its compositional components. 
     The consumable  200  shown in  FIG. 1  comprises a mouthpiece  220  and a vapour generating substance  210 . The vapour generating substance  210  may be solid, semi-solid or a liquid and generates a vapour upon heating. In this example, the vapour generating substance  210  is tobacco. After the vapour has been generated it is drawn through the consumable  200  and is inhaled by the user at the mouthpiece  220 . The consumable  200  of  FIG. 1  is substantially cylindrical with a straight stick or rod shape however this is not necessary and consumables  200  with alternate shapes are possible as long as they fit into the heating chamber  110  of the device  100 . An example of a consumable with an alternate shape is a crooked rod where the mouthpiece  220  is angularly offset from the vapour generating substance  210 . 
     The body  101  of the device  100  is formed such that the device  100  is able to be held and operated by a single hand of the user. In the example shown in  FIG. 1 , the device  100  is shaped to have an elongate cross section in the plane perpendicular to a longitudinal axis of the device  302  so that it may be comfortably and securely held by the user. The body  101  may be fashioned such that it innately acts as a grip  120  or, alternatively, the grip  120  may be an additional component connected to the outer faces of the body. This grip  120  enhances the comfort and secureness of the device  100  when held and operated. Preferably, the perimeter of the grip  120  is between 30 mm and 160 mm so as to ensure the device  100  may be comfortably held by the user. 
     The heating chamber  110  of the invention comprises an opening  114  and an internal surface  111  extending in a first direction  301 . In a preferred example, the opening  114  of the heating chamber  110  is bevelled to allow for easier introduction of the consumable  200 . When the consumable  200  is introduced to the heating chamber  110  it is received along the first direction  301  and enters into direct contact with the internal surface  111 . 
     As shown in  FIG. 1 , the heating chamber  110  is arranged such that the axis of the first direction  301  and the longitudinal axis of the device  302  are not parallel to each other. Preferably these two axes form an angle between them in the range of 5° and 45°. Due to this arrangement, the device  100  possesses an ergonomic form which leads to an enhanced smoking experience. 
     Dimensions of the heating chamber  110  are approximately the same as the consumable  200  to allow frictional force between the consumable  200  and the internal surface  111  of the heating chamber  110  to reliably retain the consumable  200  in the heating chamber  110 . There may also be provided on the consumable  200  and/or the heating chamber  110  a non-permanent fixing means or locking mechanism to more securely retain the consumable  200  in the heating chamber  110  while still allowing for the later removal of the consumable  200 . 
     The device  100  is further provided with an air inlet  115  and an inlet passage  116  to link the exterior of the device  100  to the heating chamber  110 . This allows the user to draw air and generated vapour through the consumable  200  for inhalation by way of the mouthpiece  220 . Preferably, the air inlet  115  is located away from the grip  120  of the device  100  to avoid the air inlet  115  being covered by the user during operation, for example at the first end of the body  101  nearby the opening  114  of the heating chamber  110 . A close up view of the device comprising the air inlet and inlet passage is shown in  FIG. 2 . 
     A heating element  112  is arranged nearby the heating chamber  110  of the device  100  to provide a means of transferring heat to the vapour generating substance  210 . As shown in  FIGS. 1 and 2 , the heating element  112  surrounds the heating chamber  110  so as to uniformly heat the substance  210  and generate the vapour more efficiently. Positioning the heating element  112  closer to the heating chamber  110  further increases the power efficiency of the device  100  as less heat is lost between the heating element  112  and heating chamber  110 . Examples of possible heating elements  112  are a heater, such as a film resistive heater, and an electromagnetic inductor. The device  100  may be provided with a thermal insulator  113  to protect heat sensitive components of the device  100  from heat generated by the heating element  112 . The thermal insulator  113  may additionally increase the power efficiency of the device  100  as less heat is transferred to components other than the heating chamber  110  and consumable  200 . In this example the thermal insulator  113  surrounds both the heating element  112  and the heating chamber  110  however other locations and arrangements may provide further benefits. For example, the thermal insulator  113 , or an additional thermal insulator, may be disposed nearby the PCB  140  or battery  130 , so that the insulator  113  is between the heating element  112  and the PCB  140  or battery  130 , if these components are particularly heat sensitive. 
     The device  100  shown in  FIG. 1  comprises a PCB  140  and battery  130  which are arranged substantially parallel to the longitudinal axis of the device  302 . The PCB  140  and battery  130  are arranged in this manner to maximise usage of internal space of the device  100  while mitigating the risk that these components are damaged by the heating element  112 . The battery  130  provides power to the components of the device  100  and is connected to, for example, the PCB  140  and heating element  112 . There may also be provided an activation means such as a switch or button  116  to allow the user to selectively apply power to the heating element  112 .  FIG. 1  also shows a possible internal region of the device where other components  150  may be disposed if required. 
     In some examples the device  100  may further comprise a user interface  160  as a means of displaying information. Displayed information may include the battery power level or an indicator as to whether the temperature of the heating chamber  110  is sufficient to heat the consumable  200  and generate a vapour. 
       FIGS. 3A-B  show an example of the aerosol generating device  100  where the device  100  has a elongate cross section in the plane perpendicular to the longitudinal axis of the device  302 . Preferably, the elongate cross section has a minimum width  303  in the range of 15 mm and 25 mm and a maximum width  304  in the range of 25 mm and 50 mm. 
       FIGS. 4A-B  show an alternate example of the aerosol generating device  100  with a substantially circular cross section in the plane perpendicular to the longitudinal axis of the device  302 . Preferably, the substantially circular cross section has a diameter  305  in the range of 10 mm and 35 mm. 
       FIGS. 5A-B  show another alternate example of the aerosol generating device  100  with a substantially ovoid cross section in the plane perpendicular to the longitudinal axis of the device  302 . Preferably, the substantially ovoid cross section has a minimum diameter  306  in the range of 15 mm and 25 mm and a maximum diameter  307  in the range of 25 mm and 50 mm. 
     As will be appreciated from the above description, the present invention provides an aerosol generating device  100  and aerosol generating system with a heating chamber  110  and grip  120  which are angularly offset to one another. This allows for the user to hold the device  100  in a more comfortable and natural position which particularly improves the smoking experience during vapour inhalation as well as the consumable  200  replacement process.