Patent Description:
The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers) has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. Various devices and systems are available that heat or warm aerosolisable substances as opposed to burning tobacco in conventional tobacco products.

A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn device. Devices of this type generate an aerosol or vapour by heating an aerosol substrate that typically comprises moist leaf tobacco or other suitable aerosolisable material to a temperature typically in the range <NUM> to <NUM>. Heating an aerosol substrate, but not combusting or burning it, releases an aerosol that comprises the components sought by the user but not the toxic and carcinogenic byproducts of combustion and burning. Furthermore, the aerosol produced by heating the tobacco or other aerosolisable material does not typically comprise the burnt or bitter taste resulting from combustion and burning that can be unpleasant for the user and so the substrate does not therefore require the sugars and other additives that are typically added to such materials to make the smoke and/or vapour more palatable for the user.

The released aerosol is typically drawn out of the device by a user inhaling through a mouthpiece. The inhaling creates air flow through the device which carries the aerosol to the user. However, if an air flow path from the heated substrate to the mouthpiece is inadequately sealed, air may flow to the user from elsewhere, meaning that the user must inhale harder or for longer to obtain a same amount of aerosol.

Accordingly, it is desirable to provide an aerosol generating device with improved sealing of an air flow route through the device.

<CIT> describes a method for providing an aerosol-generating device for use with a shape-transformable aerosol-forming substrate, which comprises providing an aerosol-generating device comprising a device housing comprising a moulding cavity. The moulding cavity at least partially corresponds to a moulding space between a first mould half and a second mould half of a mould, the first mould half and the second mould half being internal surfaces of the device housing. The method further comprises the step of providing a flat aerosol-forming substrate adapted to change shape when pressed into the moulding cavity and being transformed into a non-flat aerosol-forming substrate. The document also refers to a flat aerosol-generating article and a kit comprising a flat aerosol-generating article and an aerosol-generating device. In one example, the device has a body portion in the form of a box comprising a lid. The internal surface of the box is provided with undulations forming a first mould half. The internal surface of the lid is provided with a series of perpendicularly arranged undulations forming a second mould half.

<CIT> describes a shisha device that includes a vessel, an aerosol-generating element in fluid communication with the vessel, and a chamber between the vessel and the aerosol-generating element. The chamber is in fluid communication with the vessel and the aerosol-generating element. The chamber comprises an inlet configured to accelerate air containing aerosol that flows through the inlet from the aerosol-generating element. The chamber may include a main chamber in fluid communication with the inlet. The main chamber may be sized and shaped to allow deceleration of the aerosol in the main chamber when the aerosol exits the inlet and enters the main chamber.

<CIT> describes an aerosol-generating device for use with an aerosol-generating article comprising an aerosol-forming substrate, the device comprising a housing, an opening in the housing, a chamber, a heater, a compressor, an airflow inlet, an airflow outlet, a device first end, a device second end and a device side wall between the device ends, where the opening in the housing leads to the chamber and the device is configured to receive an aerosol-generating article through the opening and into the chamber, where the device is configured in use to channel airflow through the article, where the chamber comprises a chamber heater section comprising the heater, where the chamber comprises a chamber compression wall and the compressor is configured in use to press the article against the chamber compression wall.

According to a first aspect, the present invention provides an aerosol generating device comprising first and second housing elements configured to move between an open position and a closed position, wherein, in the closed position, the first and second housing elements together define an aerosol generation chamber configured to enclose a portion of aerosol generating substrate, and further define an air flow channel comprising an inlet, an outlet and the aerosol generation chamber, wherein the first and/or second housing element comprises a sealing member configured to seal at least part of the air flow channel between the inlet and outlet, in the closed position.

By providing a sealing member, air leaking between the first and second housing elements is reduced, and the air flow through the aerosol generating device can be more precisely designed to improve heating efficiency and quality of the generated aerosol.

The first and second housing elements are configured to engage with each other to define the aerosol generation chamber by moving along an approach direction, wherein the sealing member comprises a wall member extending in the approach direction.

By providing a wall member extending in the approach direction, a seal is established when the first and second housing elements meet at the closed position.

Optionally, one of the first and second housing elements comprises the wall member, the other of the first and second housing elements comprises a sliding contact wall extending in the approach direction, and the wall member is configured to slide against the sliding contact wall when the first and second housing elements move near the closed position.

By configuring the wall member to slide against the sliding contact wall, the seal is still effective even if the first and second housing elements are not exactly in the closed position. In other words, the user does not have to precisely position the housing elements to establish a seal.

Optionally, the wall member comprises a first wall portion extending along the air flow channel.

A wall member extending in the approach direction and along the air flow channel has the effect of preventing sideways leaking of air to or from the air flow channel between the housing elements. This reduces cooling from air leaking into the air flow channel, and reduces aerosol loss from air leaking out of the air flow channel.

Optionally, the wall member comprises a second wall portion extending along a closed end of the air flow channel.

By sealing an end of the air flow channel, it can be ensured that air flows from the inlet to the outlet.

Optionally, the wall member extends continuously from a first end at an open end of the air flow channel, around the aerosol generation chamber, to a second end at the open end of the air flow channel.

In other words, the wall member forms an open loop around the air flow channel. This provides a simple, robust construction for sealing an end of the air flow channel and sealing sides of the air flow channel.

Optionally, the first or second housing element comprises a through hole connected to the inlet or outlet of the air flow channel.

This arrangement with a through hole allows the inlet or outlet to be more precisely defined than a shape which relies on the first and second housing elements being in a specific closed position.

Optionally, the inlet or outlet is a gap between the first and second housing elements in the closed position, the gap corresponding to an open end of the air flow channel.

By providing the inlet or outlet as a gap between the housing elements, the inlet or outlet can be easily cleaned. This is particularly advantageous for the outlet, which may be expected to come into contact with a mouth of a user of the aerosol generation device.

Optionally, the first and second housing elements are attached by a hinge.

Attaching the housing elements by a hinge means that the open and closed positions can be defined as ends of a one-dimensional range of motion, making the device easy for a user to operate.

Optionally, the hinge is arranged at an end of the air flow channel opposing the gap.

This configuration with a gap opposite the hinge addresses the issue that the end of the housing elements that is furthest from the hinge has the largest range of motion, and thus is the most difficult to seal effectively.

Optionally, the device has an alligator configuration in which a mouthpiece end is configured to open around the hinge, and the first or second housing element extends beyond the hinge to provide a handle end.

This configuration is particularly straightforward to operate, because the aerosol generating device can be held by hand in a same position on the handle end both for inhaling aerosol through the mouthpiece and for moving the housing elements to the open position to replace the portion of aerosol generating substrate.

Optionally, the sealing member comprises an elastomer material.

Optionally, the first housing element comprises an open-top chamber configured to receive the portion of aerosol generating substrate, and the second housing element comprises a moveable cover for closing the chamber.

Optionally, the first housing element comprises a platform portion protruding from a main surface, wherein the open-top chamber is formed in the platform portion, the moveable cover is configured to engage with the platform portion and the main surface, and the sealing member is arranged on a side wall of the platform portion or is arranged on a surface of the moveable cover configured to engage with the side wall of the platform portion.

The platform portion and the moveable cover which engages with it provide a mating surfaces that extend along the approach direction, inhibiting air flow outside of the air flow channel. At the same time, the platform increases a depth of the first housing element available to fit the open-top chamber, meaning that the overall device can be thinner for a given size of the open-top chamber.

Optionally, the first housing element comprises a heating element arranged at a bottom surface of the open-top chamber.

Optionally, the second housing element comprises an inner surface arranged to face the open-top chamber in the closed position, wherein the inner surface comprises a thermally conductive material.

The thermally conductive material has the effect of increasing the evenness of heating the portion of aerosol generating substrate.

<FIG> is a schematic illustration of a first housing element <NUM> of an aerosol generating device <NUM>, and <FIG> is a schematic illustration of a second housing element <NUM> of the aerosol generating device <NUM>. The main bodies of the first and second housing elements <NUM>, <NUM> may, for example, be made from a medical grade high temperature plastic material. Preferably, the plastic material is a 3D printable material.

The first and second housing elements <NUM> and <NUM> are attached to each other by an attachment means <NUM>, and are configured to move relative to each other between an open position and a closed position.

The attachment means <NUM> may, for example, be a hinge or a flexible portion of housing that confines the relative motion of the first and second housing elements <NUM> and <NUM> to a predetermined path of motion. Alternatively, the first and second elements <NUM> and <NUM> may be more generally attached, for example with a cable. Additionally or alternatively the first and second housing elements <NUM> and <NUM> may be entirely separable. For example, the attachment means <NUM> may be a detachable element such as a clip, or may be omitted entirely.

When the aerosol generating device <NUM> is in the closed position, the first and second housing elements <NUM> and <NUM> together define an air flow channel <NUM> comprising an inlet <NUM> and an outlet <NUM>.

In the example illustrated in <FIG>, the air flow channel <NUM> is defined between a surface <NUM> of the first housing element <NUM> and a surface <NUM> of the second housing element <NUM>.

Additionally, when the aerosol generating device <NUM> is in the closed position, the first and second housing elements <NUM> and <NUM> together define an aerosol generation chamber <NUM> configured to enclose a portion of aerosol generating substrate.

Referring to <FIG>, in the illustrated example the aerosol generation chamber is formed from an open-top chamber <NUM> in the first housing element <NUM> configured to receive the portion of aerosol generating substrate, and from a surface <NUM> of the second housing element <NUM> functioning as a moveable cover for the aerosol generation chamber <NUM>. The open-top chamber <NUM> may simply be a recess in the surface <NUM> of the first housing element <NUM>.

When the aerosol generating device <NUM> is in the open position, the first housing element <NUM> is spaced apart from the second housing element <NUM>, and the user can access the open top chamber <NUM>. In this position, the user can add or remove the portion of aerosol generating substrate. In particular, as aerosol is generated, the substrate is consumed and so it must be periodically replaced by moving the first and second housing elements <NUM>, <NUM> to the open position. On the other hand, when the aerosol generating device <NUM> is in the closed position, the surface <NUM> covers the aerosol generation chamber <NUM>, and the portion of aerosol generating substrate can be efficiently heated to generate aerosol.

The aerosol generating substrate (not shown) may for example comprise nicotine or tobacco and an aerosol former. Tobacco may take the form of various materials such as shredded tobacco, granulated tobacco, tobacco leaf and/or reconstituted tobacco. Suitable aerosol formers include: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, acids such as lactic acid, glycerol derivatives, esters such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerin or vegetable glycerin. In some examples, the aerosol generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The substrate may also comprise at least one of a gelling agent, a binding agent, a stabilizing agent, and a humectant.

The portion of aerosol generating substrate is preferably shaped to fit in the open-top chamber <NUM>. For example, the portion may be substantially cuboid having a length L and width W corresponding to the open-top chamber <NUM>.

When the aerosol generating device <NUM> is in the closed position, the air flow channel <NUM> intersects with the aerosol generation chamber <NUM>, such that aerosol generated in the aerosol generation chamber <NUM> can be drawn along the air flow channel <NUM> towards the outlet <NUM>.

Each of the first and second housing elements <NUM> and <NUM> in this example comprises a wall portion <NUM>, <NUM> adjacent to the air flow channel <NUM>. In the closed position, the wall portions <NUM>, <NUM> define a wall of the air flow channel <NUM> between the inlet <NUM> and the outlet <NUM>.

However, the open position and closed position each have a certain tolerance. The user of the aerosol generating device <NUM> may not firmly close the device <NUM> meaning that there is at least some gap between the first and second housing elements <NUM>, <NUM>, even in the closed position. As a result, there is a need to improve sealing in the closed position.

In order to improve the seal of the air flow channel <NUM> in the closed position, a sealing member <NUM> is provided on the first housing element <NUM>. The sealing member <NUM> is configured to seal at least part of the air flow channel between the inlet <NUM> and outlet <NUM>, in the closed position. By improving the sealing of the air flow channel <NUM>, air flow from the inlet <NUM> to the outlet <NUM> is increased, and leakage of air through other gaps between the first and second housing elements <NUM> and <NUM> is reduced. Since the sealing member <NUM> is configured to seal between the first and second housing elements <NUM> and <NUM>, the sealing member <NUM> may be attached to either of the first housing element <NUM> and second housing element <NUM>, and/or may contain a first section attached to the first housing element <NUM> and a second section attached to the second housing element <NUM>.

In order to further explain the sealing member <NUM>, it is useful to refer to a cross-section along line X1 of <FIG>, as shown in <FIG>. In <FIG>, the aerosol generation device <NUM> is in the open position and, in <FIG>, the aerosol generation device <NUM> is in the closed position.

More specifically, in the first example, the first and second housing elements <NUM>, <NUM> are configured to engage with each other to define the aerosol generation chamber <NUM> by moving along an approach direction illustrated with an arrow in <FIG>.

The sealing member <NUM> comprises a first wall member <NUM> attached to the second housing element <NUM> and extending in the approach direction such that, as the first and second housing elements <NUM>, <NUM> approach the closed position, the sealing member <NUM> can be compressed and deformed to form a tight seal against the first housing element <NUM>.

In order to provide this compression and deformation behaviour, the sealing member <NUM> is preferably made from an elastic material such as an elastomer. The elastic material may, for example, be a food-proof silicone.

As shown in <FIG>, the first wall member <NUM> extends along a closed end <NUM> of the air flow channel <NUM>. At the same time, the inlet <NUM> comprises a through hole through the second housing element <NUM>. The through hole could equally be formed through the first housing element <NUM>. By using a through hole instead of a gap between the first and second housing elements <NUM>, <NUM> to define the inlet <NUM>, the shape of the inlet <NUM> can be more precisely defined.

In some examples, the outlet <NUM> may also or alternatively comprise a through hole. However, in this example, the outlet <NUM> is a gap between the first and second housing elements in the closed position, the gap corresponding to an open end of the air flow channel.

More specifically, the outlet <NUM> comprises a gap at an end of the air flow channel <NUM> opposing the attachment means <NUM> (in this case, a hinge). The combination of a gap outlet <NUM> between the housing elements at one end of the air flow channel, and a hinge <NUM> at or beyond the other end of the air flow channel, has the effect that it is not necessary to attempt to seal the first and second housing elements <NUM>, <NUM> at the point which has the widest range of motion because it is furthest from the hinge, and therefore the point that would otherwise be the most difficult to seal along the air flow channel <NUM>.

<FIG> also illustrate several other optional features of aerosol generating devices <NUM>.

The aerosol generation chamber <NUM> of this example comprises a heating element <NUM> for heating the portion of aerosol generating substrate to generate the aerosol. In other examples, the aerosol generation chamber <NUM> may instead generate the aerosol via other means, such as by vibration.

The heating element may, for example, be an electrically-resistive track. Alternatively, the heating element may generate heat by a chemical reaction such as combustion.

The heating element may a planar heating element arranged on or within a surface of the recess <NUM> or the surface <NUM>. Alternatively, the heating element may be connected to either of these surfaces <NUM>, <NUM> via one or more thermally conductive portions such as portions of metal.

Additionally, in this example, the first housing element <NUM> comprises a handle end <NUM> extending beyond the attachment means <NUM>. The handle end <NUM> provides a part of the aerosol generating device <NUM> which can be held by hand, while moving the first and second housing elements <NUM>, <NUM> between the open position and the closed position.

The handle end <NUM> can also be used for enclosing parts of the aerosol generating device <NUM> which are not directly involved in air flow or aerosol generation. For example, the handle end <NUM> may contain control circuitry <NUM> and/or a power supply <NUM> (such as a battery). The handle end <NUM> could, in other examples, instead be an extension of the second housing element <NUM>.

The combination of the handle end <NUM> at one end of the aerosol generating device <NUM>, the attachment means <NUM> in a middle point, and a mouthpiece end comprising the outlet <NUM> which opens to provide access to the aerosol generation chamber <NUM> when in the open position, can be described as an "alligator" configuration. The "alligator" mechanism has several advantages including making it easier to operate and clean the air flow channel <NUM> and the aerosol generation chamber <NUM>, and decreasing a required thickness of the aerosol generating device <NUM> by providing space for components beyond an openable hinged section.

Furthermore, in this example, the second housing element <NUM> comprises an inner surface <NUM> arranged to face the open-top chamber <NUM> in the closed position, wherein the inner surface comprises a thermally conductive material.

For example, the inner surface <NUM> may comprise a metal such as stainless steel or aluminium. By providing such a thermally conductive surface, the temperature in the air flow channel <NUM> is more uniform, and the quality of the condensed aerosol is improved. Additionally, a metal surface <NUM> makes the aerosol generating device <NUM> more robust and easier to clean.

<FIG> illustrate a cross-section along line X2 in <FIG>. <FIG> shows cross-sections of the first and second housing elements <NUM>, <NUM> when they are separated in the open position, and <FIG> shows cross-sections of the first and second housing elements when they are adjacent in the closed position.

In particular, <FIG> illustrate a sealing member <NUM> in the form of a second wall member <NUM> extending along the air flow channel <NUM>. The second wall member <NUM> may be provided in addition or alternative to the first wall member <NUM> described above.

Furthermore, as shown in <FIG>, the first and second wall members <NUM>, <NUM> may be combined to provide a wall member extending continuously from a first end at an open end of the air flow channel, around the aerosol generation chamber, to a second end at the open end of the air flow channel. In the present example, the open end is the outlet <NUM>, although the open end could instead be the inlet <NUM>. By providing a continuous sealing member along sides and an end of the air flow channel <NUM>, the sealing of the air flow channel is further improved.

Preferably, each wall member <NUM>, <NUM> is configured to meet a sliding contact wall <NUM> near the closed position. More specifically, a sliding contact wall here means a wall extending in the approach direction on one of the first and second housing elements <NUM>, <NUM> and configured so that a wall member <NUM>, <NUM> on the other of the first and second housing elements <NUM>, <NUM> slides against the sliding contact wall <NUM> as the first and second housing elements <NUM>, <NUM> move near the closed position. By providing a sliding contact between the wall member <NUM>, <NUM> and an opposing wall, the sealing member <NUM> can provide a sealing effect over a range of relative positions of the first and second housing elements <NUM>, <NUM> so that the air flow channel <NUM> is sealed even if the first and second housing elements <NUM>, <NUM> are not precisely in the closed position.

<FIG> and <FIG> are schematic illustrations of an aerosol generating device <NUM> according to a second example, with the first and second housing elements <NUM>, <NUM> in different relative positions. The second example is largely similar to the first example, but has additional optional features.

In the second example, the air flow channel <NUM> and the open-top chamber <NUM> take the form of recesses in a platform portion protruding from a surface of the first housing element <NUM>. The moveable cover <NUM> is configured to engage with a top surface <NUM> of the platform portion and with a main surface of the wall portion <NUM>.

The platform portion has a sliding contact wall <NUM> extending along continuously along two sides of the air flow channel <NUM> and along a closed end <NUM> of the air flow channel <NUM>, thus providing a surface to engage with a wall member <NUM> of the sealing member <NUM> extending continuously along the two sides and the closed end <NUM> of the air flow channel. Equally, the sliding contact wall <NUM> and the continuous wall member <NUM> could be reversed, so that the continuous wall member is arranged on the side wall of the platform portion, and the sliding contact wall is the corresponding surface on the second housing element <NUM>.

The platform portion may be made from a different material from a main body of the first and second housing elements <NUM>, <NUM>. For example, the platform portion may be made from polyether ether ketone (PEEK) which has good mechanical properties at high temperatures for heating an aerosol generating substrate, and has low thermal conductivity. Additionally, PEEK can be food safe, so that nothing is added to the generated aerosol.

Additionally, in the second example, the attachment means <NUM> is another hinge. However, in this example the hinge <NUM> is set in a plane of the air flow channel <NUM>, so that the sealing element <NUM> can more easily form a seal by moving in the approach direction.

Furthermore, as shown in <FIG> and <FIG>, examples may include a locking element <NUM> for releasably locking the first and second housing elements <NUM>, <NUM> in the closed position. For example, the locking element <NUM> may take the form of a pair of magnets or a clip.

<FIG> additionally illustrates an example where a heating element <NUM> is formed on a bottom surface of the open-top chamber <NUM>. In this case, the heating element <NUM> comprises a resistive track.

<FIG> is a schematic illustration of a first housing element <NUM> of an aerosol generating device <NUM> according to a third example, and <FIG> is a schematic illustration of a second housing element <NUM> of the aerosol generating device <NUM> according to the third example.

The third example illustrates a possible variation of the aerosol generating device <NUM>. Specifically, in this example, the wall portion <NUM> is omitted from the second housing element <NUM>, and the wall portion <NUM> of the first housing element <NUM> extends up to an upper external surface of the aerosol generating device <NUM>. As a result, when the first and second housing elements <NUM>, <NUM> are in the closed position, any gap between the first and second housing elements <NUM>, <NUM> cannot extend to an external side of the aerosol generating device <NUM>.

Additionally, in the third example, the inlet <NUM> is not a through hole in either of the first and second housing elements <NUM>, <NUM>. Instead, a notch is provided in the second housing elements <NUM> such that, when the aerosol generating device is in the closed position, a gap is formed between the first and second housing elements <NUM>, <NUM>, adjacent to the attachment means <NUM>.

<FIG> is a schematic illustration of an aerosol generating device <NUM> according to a fourth example, illustrating a further possible modification of the above described examples.

Specifically, in this example, the "alligator" configuration is replaced with a configuration in which the attachment means <NUM> is arranged close to an end of the device. The end of the device has the outlet <NUM> of the air flow channel <NUM>.

Claim 1:
An aerosol generating device comprising first and second housing elements (<NUM>, <NUM>) configured to move between an open position and a closed position, wherein:
in the closed position, the first and second housing elements together define an aerosol generation chamber (<NUM>) configured to enclose a portion of aerosol generating substrate, and further define an air flow channel (<NUM>) comprising an inlet (<NUM>), an outlet (<NUM>) and the aerosol generation chamber,
the first and/or second housing element comprises a sealing member (<NUM>) configured to seal at least part of the air flow channel between the inlet and outlet, in the closed position,
the first and second housing elements are configured to engage with each other to define the aerosol generation chamber by moving along an approach direction, characterised in that
the sealing member comprises a wall member (<NUM>, <NUM>) extending in the approach direction.