Patent Description:
Heat-not-burn (HNB) devices heat tobacco at temperatures lower than those that cause combustion to create an inhalable aerosol containing nicotine and other tobacco constituents, which is then made available to the device's user. Unlike traditional cigarettes, the goal is not to burn the tobacco, but rather to heat the tobacco sufficiently to release the nicotine and other constituents through the production of aerosol. Igniting and burning the cigarette creates unwanted toxins that can be avoided using the HNB device. However, there is a fine balance between providing sufficient heat to effectively release the tobacco constituents in aerosol form and not burn or ignite the tobacco. Current HNB devices have not found that balance, either heating the tobacco at temperatures that produce an inadequate amount of aerosol or over heating the tobacco and producing an unpleasant or "burnt" flavor profile. Additionally, the current methodology leaves traditional HNB device internal components dirtied with burning tobacco byproducts and the byproducts of accidental combustion.

For the foregoing reasons there is a need for an aerosol producing device that provides its user the ability to control the power of the device, which will affect the temperature at which the tobacco will be heated via the inductive method to reduce the risk of combustion - even at what would otherwise be sufficient temperatures to ignite - while increasing the efficiency and flavor profile of the aerosol produced.

<CIT> relates to an article for use with an apparatus for heating smokable material. <CIT> discloses an inhaler. <CIT> describes an aerosol-generating device with securing means. Other similar devices are known from <CIT> and <CIT>.

The present invention concerns a device for generating aerosol according to claim <NUM>. The present disclosure is directed to a system and method by which a consumable tobacco component is quickly and incrementally heated by induction, so that it produces an aerosol that contains certain of its constituents but, not with the byproducts most often associated with combustion, for example, smoke, ash, tar and certain other potentially harmful chemicals. This disclosure involves positioning and incrementally advancing heat along a consumable tobacco component with the use of an induction heating element that provides an alternating electromagnetic field around the component.

An object of the present invention is a device wherein an induction heating source is provided for use to heat a consumable tobacco component.

Another object of the present disclosure is a consumable tobacco component comprised of several, sealed, individual, airtight, coated encasements containing a consumable tobacco preparation - and an induction heating source. The encasement may be an aluminum shell with pre-set openings. The encasements may be coated with a gel that seals the openings until an inductive heating process melts the gel, clearing the openings. In some embodiments, the gel can include a flavoring agent that can add flavor to or enhance the flavor of the tobacco aerosol.

In some embodiments, multiple encasements are stacked inside a paper tube with spaces between them, formed by excess aluminum wrapping at the bottom end of each encasement and channels on either side to allow for the aerosol produced. When the inductive heating source is activated, the pre-set openings are cleared, and flavor is combined with the aerosol to travel through the tube and be made available to the user of the device.

Using these methods and apparatus, the device is required to heat less mass, can heat-up immediately, cool down quickly and conserve power, allowing for greater use between recharging sessions. This contrasts with the well-known, current, commercially available heat-not-burn devices.

Another object of the present disclosure is a tobacco-containing consumable component comprised of several, sealed, individual, airtight, coated encasements and an induction heating source. The encasements are then coated with a gel that seals them until an inductive heating process can melt the gel, clearing the openings. In some embodiments, the gel can include a flavoring agent that can add flavor to or enhance the flavor of the consumable tobacco component.

Another object of the present disclosure is to create a consumable-containing package that is easy to replace and minimizes fouling the inside of the case during use so as to reduce cleaning efforts of the case.

Another object of the present disclosure is to move the heating element relative to the susceptor or the consumable to heat segments of the consumable independent of other segments.

Another object of the invention is to maximize the efficiency of energy usage in the device for generating aerosol.

Another object of the invention is to control the heat of the heating element to maximize the longevity of the device.

Another object is to create the ability to change the airflow through the device to change the flavor or dosage of a consumable.

An embodiment which is fully in accordance with the present invention, as defined in claim <NUM>, is for example presented in <FIG> together with <FIG>.

The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments.

The invention of the present application is a device for generating aerosols from a consumable-containing product for inhalation in a manner that utilizes relatively high heat with minimal burning of the consumable-containing product. For the purposes of this application, the term "consumable" is to be interpreted broadly to encompass any type of pharmaceutical agent, drug, chemical compound, active agent, constituent, and the like, regardless of whether the consumable is used to treat a condition or disease, is for nutrition, is a supplement, or used for recreation. By way of example only, a consumable can include pharmaceuticals, nutritional supplements, over-the-counter medicants, tobacco, cannabis, and the like.

With reference to <FIG>, the device <NUM> comprises a consumable-containing package <NUM> and an aerosol producing device <NUM>. The device <NUM> generates aerosols through a heat-not-burn process in which a consumable-containing unit <NUM> is heated to a temperature that does not burn the consumable-containing unit <NUM>, but does release the consumable from the consumable-containing unit in the form of an aerosol product that can be inhaled. Thus, a consumable-containing unit <NUM> is any product that contains a consumable that can be released into aerosol form when heated to the proper temperature. The present application discusses application of the invention to a tobacco product to provide a concrete example. The invention, however, is not limited to use with tobacco products.

With reference to <FIG>, the consumable-containing package <NUM> is the component that is heated to release the consumable in aerosol form. The consumable-containing package <NUM> comprises a consumable-containing unit <NUM>, a metal (also referred to as the susceptor) <NUM> for heating the consumable-containing unit <NUM> through an inductive heating system, and an encasement <NUM> to contain the consumable-containing unit <NUM> and the susceptor <NUM>. How well the consumable-containing package <NUM> is heated is dependent on product consistency. Product consistency takes into consideration various factors, such as the position, shape, orientation, composition, and other characteristics of the consumable-containing unit <NUM>. Other characteristics of the consumable-containing unit <NUM> may include the amount of oxygen contained in the unit. The goal is to maximize product consistency by keeping each of these factors consistent in the manufacturing process.

If the form of the consumable-containing unit <NUM> is in direct physical contact with the susceptor <NUM> with maximal contact area between each, then it can be inferred that the thermal energy induced in the susceptor <NUM> will be largely transferred to the consumable-containing unit <NUM>. As such, the shape and arrangement of the consumable-containing unit <NUM> relative to the susceptor <NUM> is an important factor. In some embodiments, the consumable-containing unit <NUM> is generally cylindrical in shape. As such, the consumable-containing unit <NUM> may have a circular or oval-shaped cross-section.

In addition, another objective with respect to the design of the consumable-containing unit <NUM> is to minimize the amount of air to which the consumable-containing unit <NUM> is exposed. This eliminates or mitigates the risk of oxidation or combustion during storage or during the heating process. As a result, at certain settings, it is possible to heat the consumable-containing unit <NUM> to temperatures that would otherwise cause combustion when used with prior art devices that allow more air exposure.

As such, in the preferred embodiment, the consumable-containing unit <NUM> is made from a powdered form of the consumable that is compressed into a pellet or rod. Compression of the consumable reduces the oxygen trapped inside the consumable-containing unit <NUM>. In some embodiments, the consumable-containing unit <NUM> may further comprise an additive, such as a humectant, flavorant, filler to displace oxygen, or vapor-generating substance, and the like. The additive may further assist with the absorption and transfer of the thermal energy as well as eliminating the oxygen from the consumable-containing unit <NUM>. In an alternative embodiment, the consumable may be mixed with a substance that does not interfere with the function of the device, but displaces air in the interstitial spaces of the consumable and/or surrounds the consumable to isolate it from the air. In yet another alternative embodiment, the consumable could be formed into tiny pellets or other form that can be encapsulated to further reduce the air available to the consumable.

As shown in <FIG>, in the preferred embodiment, the consumable-containing unit <NUM> may be one elongated unit defining a longitudinal axis L. For example, the consumable-containing unit <NUM> may be an elongated cylinder or tube having a circular transverse cross-section or an oval transverse cross-section. As such, the consumable-containing unit <NUM> may be defined by two opposing ends <NUM>, <NUM> and a sidewall <NUM> therebetween extending from the first end <NUM> to the second end <NUM> defining the length of the consumable-containing unit <NUM>.

The susceptor <NUM> may be similarly elongated and embedded in the consumable-containing unit <NUM>, preferably, along the longitudinal axis L and extending substantially the length and width (i.e. the diameter) of the consumable-containing unit <NUM>. In consumable-containing units <NUM> having an oval cross-section, the diameter refers to the major diameter defining the long axis of the oval.

The susceptor <NUM> can be machine extruded. Once extruded, the consumable-containing unit <NUM> can be compressed around the susceptor <NUM> along the length of the susceptor <NUM>. Alternatively, the susceptor <NUM> could be stamped from flat metal stock or any other suitable method of fabrication prior to assembling the consumable containing unit <NUM> around the susceptor <NUM>. In some embodiments, as shown in <FIG>, the susceptor <NUM> may be made of steel wool. For example, the susceptor <NUM> may be comprised of fine filaments of steel wool bundled together in the form of a pad. As such, the steel wool pad comprises numerous fine edges. In some embodiments, the steel wool pad may be doused with, immersed in, or fully filled with the additive, such as a humectant, flavorant, vapor-generating substance, a substance to retard oxidation of the steel wool (rust), and/or a filler to eliminate air between the steel wool filaments, and the like. As shown in <FIG>, there may be cut-outs along the steel wool pad to divide the consumable containing unit <NUM> into discrete segments for individual heating, as described below. Alternatively, individual pads of steel wool may be used, separated by space and/or consumable, so that each pad may be heated individually during use.

Advantages of the steel wool, include, but are not limited to, easy disposability from an environmental standpoint in that it begins to oxidize soon after it is heated; and thereby, becomes friable and degrades easily without dangerous sharp edges. Being composed of iron and carbon it is relatively non-toxic.

The susceptor <NUM> can be made of any metal material that generates heat when exposed to varying magnetic fields as in the case of induction heating. Preferably, the metal comprises a ferrous metal. To maximize efficient heating of the consumable-containing unit <NUM>, the susceptor <NUM> generally matches the shape of the largest cross-sectional area of the consumable-containing unit <NUM> so as to maximize the surface area with which the consumable-containing unit <NUM> comes into contact with the susceptor <NUM>, but other configurations may also be used. In the embodiments in which the consumable-containing unit <NUM> is an elongated cylinder, the largest cross-sectional area would be defined by dividing the elongated cylinder down the longitudinal axis L along its major diameter creating a rectangular cross-sectional area. As such, the susceptor <NUM> would also be rectangular with dimensions substantially similar to the dimensions of the cross-sectional area of the elongated cylinder.

In some embodiments, the susceptor <NUM> may be a metal plate. In some embodiments, the susceptor <NUM> may be a metal plate with a plurality of openings <NUM>, like a mesh screen. Inductive heating appears to be most effective and efficient at the edges of the susceptor <NUM>. A mesh screen creates more edges in the susceptor <NUM> that can contact the consumable-containing unit <NUM> because the edges define the openings <NUM>.

Preferably, the susceptor <NUM> may be a strip patterned with an array of small openings <NUM> to increase the amount of edges that can be utilized in an efficient inductive heating process, followed by a larger gap <NUM> that allows for that length of the susceptor <NUM> that will not allow for inductive heating, or at least mitigate inductive heating and/or mitigate conduction from the segment being heated. This configuration allows for the consumable-containing package <NUM> to be heated in discrete segments. The elongated susceptor <NUM> may be an elongated metal plate having a longitudinal direction, the elongated metal plate comprising sets of openings 110a, 110b and sets of gaps 112a, 112b wherein the sets of openings 110a, 110b alternate in series with the sets of gaps 112a, 112b along the longitudinal direction of the elongated metal plate such that each set of openings 110a, 110b is adjacent to one of the gaps 112a, 112b. Therefore, moving from one end of the susceptor <NUM> to the opposite end, there is a first set of openings 110a, then a first gap 112a, then a second set of openings 110b, then a second gap 112b, and so on. In the area of the gaps <NUM>, there is very little metal material; therefore, there is minimal heat transfer. As such, even though the consumable-containing unit <NUM> is a single unit, it can still be heated in discrete sections. The consumable-containing unit <NUM> and susceptor <NUM> are then wrapped in an encasement <NUM>.

In the preferred embodiment, the encasement <NUM> may be made of aluminum with prepunched openings <NUM>. The consumable-containing unit <NUM> is placed inside the encasement <NUM> to contain the heat generated by the susceptor <NUM>. The openings <NUM> in the encasement <NUM> allow the consumable aerosol to escape when heated. Because the openings <NUM> create an avenue through which air can enter into the encasement <NUM> to be exposed to the consumable-containing unit <NUM>, the openings <NUM> may be temporarily sealed using a coating. The coating is preferably made of a composition that melts at temperatures that create consumable aerosols. Therefore, as the susceptor <NUM> is heated, due to the lack of air inside the encasement <NUM>, the consumable-containing unit <NUM> can be raised to exceedingly high temperatures without combusting. As the susceptor <NUM> reaches high temperatures, the consumable aerosols that begin to form, are not able to escape. When the coating melts away and exposes the opening <NUM>, then the consumable aerosols are able to escape the encasement <NUM> for inhalation. In the preferred embodiment, the coating may be propylene glycol alginate ("PGA") gel. The coating may also include a flavoring. Therefore, as the coating melts away and the consumable aerosol is released, the flavoring is also released with the consumable aerosol. In some embodiments, the flavoring can be mixed with the additive.

In some embodiments, the openings <NUM> may be a plurality of holes or slits. The openings <NUM> may be formed along the length of the sidewall <NUM> of the encasement <NUM>, arranged radially around the sidewall <NUM>, arranged randomly or uniformly throughout the sidewall <NUM>, and the like. In some embodiments, the openings <NUM> may be a plurality of holes along the opposite ends <NUM>, <NUM> of the encasement <NUM>. In some embodiments with the elongated consumable-containing unit <NUM>, the encasement <NUM> may also be elongated with the opening <NUM> in the form of one or more elongated slits traversing the length of the encasement parallel to the longitudinal axis L, thereby creating a seam. That seam may be folded or crimped, but still leave a gap through which consumable aerosols may travel, either along its entire length or in discrete areas. Like the openings <NUM> described above, the seam may be sealed with a coating.

The consumable-containing package <NUM> may further comprise a filter tube <NUM> to encapsulate the consumable-containing unit <NUM>, susceptor <NUM>, and the encasement <NUM>. The filter tube <NUM> may be made of filter material to capture any unwanted debris while allowing the consumable aerosol that is released from the heating of the encasement to pass transversely through the filter. The filter tube <NUM> may surround the encasement <NUM> and further cover the coated openings <NUM>. Because the filter tube <NUM> may be made of filtering material, the consumable aerosol is able to travel through the filter tube <NUM>. By way of example only, the filter tube may be made of cellulose or cellulose acetate, although any suitable filter material may be used.

The consumable-containing package <NUM> may further comprise a housing <NUM> to enclose the filter tube <NUM>. The housing <NUM> may be a paper tube. The housing <NUM> is less likely to allow the consumable aerosols to pass through. As such, the housing <NUM> wrapped around the filter tube <NUM> creates a longitudinal channel through the filter tube <NUM> through which the consumable aerosol travels, rather than escaping radially out the filter tube <NUM>. This allows the consumable aerosol to follow the path of inhalation towards the user's mouth. One end <NUM> of the housing <NUM> may be capped with an end cap <NUM>. The end cap <NUM> may be comprised of a type of filter material. At the opposite end <NUM> of the housing <NUM> is a mouthpiece <NUM> that the user sucks on to draw the heated consumable aerosol out of the encasement <NUM> along the filter tube <NUM> towards the mouthpiece <NUM> and into the user's mouth. As such, the mouthpiece <NUM> may also be a type of filter, similar to that of the end cap <NUM>. Where the consumable containing package <NUM> includes a channel through which the consumable aerosol travels, and that channel leads directly to the mouthpiece <NUM> that is also part of the consumable containing package <NUM>, and the channel is isolated from the case <NUM>, the case <NUM> will remain free of any residue or byproducts formed during operation of the device. In this configuration, the case <NUM> stays clean and does not require the user to periodically clean out the case <NUM>.

In some embodiments, the encasements <NUM> may be made of a two piece unit having a first encasement section 108a and a second encasement section 108b. The consumable-containing unit <NUM> can be inserted into the first encasement section 108a and the second encasement section 108b may be placed on top of the first encasement section 108a to cover the consumable-containing unit <NUM>. Preset openings <NUM> can be formed into the encasement <NUM> prior to encapsulating the consumable-containing unit <NUM>.

Having established the general principles of the consumable-containing package <NUM>, variations have also been contemplated that achieve the same objectives. For example, in some embodiments, the consumable-containing unit <NUM> may comprise two elongated sections 104a, 104b. The two elongated sections 104a, 104b of the consumable-containing unit <NUM> may be defined by a plane parallel to and cutting through the longitudinal axis L along the diameter. Therefore, the two elongated sections 104a, 104b may be half-cylinder sections that when mated together form a full cylindrical consumable-containing unit <NUM>.

In some embodiments, as shown in <FIG>, the consumable-containing unit <NUM> may be in the form of pellet or tablet. Unlike the consumable-containing unit <NUM> that is an elongated cylinder or tube in which the length of the sidewall <NUM> is much longer than the diameter, in the tablet embodiment, the tablet may be a short cylinder defining a longitudinal axis L, wherein the length of the sidewall <NUM> is closer to the size of the diameter, or shorter than the diameter. The susceptor <NUM> may have a flat, circular shape to match the cross-sectional shape of the tablet when cut transversely, perpendicular to the longitudinal axis L. The consumable-containing unit <NUM> can be compressed about the susceptor <NUM>. To mimic a cigarette, a plurality of the consumable-containing units <NUM> can be stacked, end-to-end along their longitudinal axes L, to form an elongated cylinder. Therefore, each individual consumable-containing unit <NUM> can be heated separately, effectively mimicking the segments of the consumable-containing unit <NUM> having an elongated, tubular body.

Other shapes can also be used, such as square or rectangular with a susceptor <NUM> having a corresponding shape. The cylindrical shape, however, is preferred because of the ease with which such shape can be used to mimic the shape of an actual cigarette.

In some embodiments, the consumable-containing unit <NUM> may be formed from two sections 104a, 104b of the consumable-containing unit <NUM> combined together to make a whole, as shown in <FIG> and <FIG>. The two sections 104a, 104b are defined by splitting the consumable-containing unit <NUM> in half transversely along a plane perpendicular to the longitudinal axis L. The susceptor <NUM> may be sandwiched in between the two sections 104a, 104b. With the susceptor <NUM> sandwiched in between the two consumable-containing sections 104a, 104b, the consumable-containing unit <NUM> can be enclosed by the encasement <NUM>. This process can be repeated to create a plurality of individual consumable-containing units <NUM> sandwiching respective susceptors <NUM>, each individually contained in a respective encasement <NUM>. The plurality of consumable-containing units <NUM> may be stacked, one on top of the other to create the consumable-containing package <NUM> in which each individual consumable-containing unit <NUM> may be heated individually, one at a time.

In some embodiments, the encasement <NUM> may be aluminum wrapped around a consumable-containing unit <NUM>. The aluminum can have excess folds <NUM>, <NUM> at opposite ends as shown in <FIG>. These excess folds <NUM>, <NUM> create a gap in between adjacent consumable-containing units <NUM> when stacked on top of each other.

In some embodiments, the encasement <NUM> may be two-pieces having a first encasement section 108a and a second encasement section 108b that serves as a covering or cap to enclose the consumable-containing unit <NUM> inside the first encasement section 108a, as shown in <FIG> and <FIG>. As described previously, the openings <NUM> on the encasement <NUM> may be along the sidewall <NUM> or at the ends <NUM>, <NUM>. As described previously, the susceptor <NUM> may be any type of metal that is subject to induced heating, including steel wool as shown in <FIG>. In the preferred embodiments, numerous edges are created in the susceptor <NUM> by creating a plurality of holes <NUM> or using steel wool filaments compressed together. The steel wool filaments may be fine to medium grade. As discussed above, the steel wool pad may be soaked in, coated, or filled with additive, flavorant, protectant, and/or filler.

In some embodiments, a plurality of consumable-containing units <NUM> may be contained in a single elongated encasement <NUM>, as shown in <FIG>. The encasement <NUM> may be molded with compartments <NUM> to receive each individual consumable-containing unit <NUM>. In some embodiments, the individual compartments <NUM> may be connected to each other by a bridge <NUM>. In some embodiments, the bridge <NUM> may define a channel <NUM> that allows fluid communication from one compartment <NUM> to another. In some embodiments, the bridge <NUM> may be crimped to prevent fluid communication between one compartment <NUM> and the other through the bridge <NUM>. In some embodiments, the elongated encasement <NUM> may be a two-piece assembly split transversely along the longitudinal axis L, as shown in <FIG>. The consumable-containing units <NUM> can be seated in the compartments <NUM> of one of the encasement sections 108a. The second encasement section 108b can then be mated to the first encasement section 108a to cover the consumable-containing units <NUM>. The split between the first encasement section 108a and the second encasement section 108b can be used as the opening <NUM>. Alternatively, preset openings <NUM> can be formed in one or both of the encasement sections 108a, 108b.

In some embodiments, as shown in <FIG>, the encasement <NUM> may be made out of material that allows the encasement <NUM> to serve as the susceptor. For example, the encasement <NUM> can be made of steel, or otherwise comprise ferrous metal, or any other metal that can be heated using induction heating. In such an embodiment, an interior susceptor <NUM> would not be required to be embedded into the consumable-containing unit <NUM>. The encasement <NUM> can still comprise a plurality of holes <NUM>, and be covered with an additive and/or sealant such as PGA. Such an embodiment can be made into an elongated tube as shown in <FIG> or into tablets or disks as shown in <FIG>. The encasement <NUM> can be a two piece encasement having a first encasement section 108a and a second encasement section 108b as discussed previously.

In some embodiments, the encasement <NUM> may have transverse slits <NUM> transversely across the encasement <NUM>, generally perpendicular to the longitudinal axis L as shown in <FIG> and <FIG>. The slits <NUM> create segmentation in the encasement <NUM> so that only a small segment of the consumable-containing unit <NUM> is heated per actuation. The transverse slits <NUM> may be through holes, which expose the consumable-containing unit <NUM> underneath. In such embodiments, the segments may be filled with a coating or some other plug to seal the hole, either permanently or with a substance that will melt upon heating and allow the aerosol to escape through the slit <NUM>. In some embodiments, the plug may be made from material that can function as a heat sink and/or a substance that is not easily heated via induction to reduce the heating effect at the transverse slits <NUM>. In some embodiments, the transverse slit <NUM> may be a recessed portion of or an indentation in the encasement <NUM>. In other words, the transverse slit <NUM> may be a thinned portion of the encasement <NUM>. As such, the transverse slit <NUM> may define a well. The well can be filled with a plug that can function as a heat sink and/or a substance that is not easily heated via induction to reduce the heat transfer along the transverse slit <NUM>.

Heating the consumable-containing unit <NUM> is achieved by an induction heating process that provides non-contact heating of a metal, preferably ferrous metal, by placing the metal in the presence of a varying magnetic field generated by an inductive heating element <NUM>, as shown in <FIG>. In the preferred embodiment, inductive heating element <NUM> is a conductor <NUM> wrapped around into a coil that generates the magnetic field when current is passed through the coil. The metal susceptor <NUM> is placed close enough to the conductor <NUM> so as to be within the magnetic field. In the preferred embodiment, the coil is wrapped in a manner that defines a central cavity <NUM>. This allows the consumable-containing package <NUM> to be inserted into the cavity <NUM> to have the coil surround the susceptor <NUM> without touching the susceptor <NUM>. The current passed through the coil is alternating current creating a rapidly alternating magnetic field. The alternating magnetic field may create eddy currents in the susceptor <NUM>, which may generate heat within the susceptor <NUM>. Thus the consumable-containing package <NUM> is generally heated from the inside out. In embodiments in which the encasement <NUM> also serves as the susceptor, the consumable-containing package <NUM> is heated from the outside in.

In the preferred embodiment, segments of the consumable-containing package <NUM> are to be heated individually. As such, the conductor <NUM> may also be provided as individual sets of coiled conductors 162a-f, as shown in <FIG>. Each conductor coil 162a-f may be attached to a controller <NUM> that can be controlled to activate one conductor coil 162a-f at a time. Although there are six (<NUM>) conductor coils 162a-f shown in <FIG>, greater or fewer coils could be used. In an alternative embodiment, a single conductor coil <NUM> may be used, with a mechanical mechanism that translates the coil along the consumable-containing package <NUM> to individually heat each segment of the consumable-containing package <NUM>.

The individual conductor coils 162a-f may match up with discrete segments of the consumable-containing package <NUM>, as described above, and shown in <FIG>. Alternatively, the conductor coils 162a-f could each correspond to a certain length of a continuous consumable-containing package <NUM> such as shown in <FIG>, <FIG>, and <FIG>, to heat only that certain length. In preliminary testing of such embodiments, heating along discrete lengths of the consumable-containing package <NUM> does not appreciably heat adjacent portions of the consumable-containing package <NUM>, as the adjacent non-heated consumable appears to act as an insulator. Thus, structures to limit heat transfer may not be necessary, although such structures have been discussed herein and may be useful.

The efficiency of conversion of electric power into thermal heat in the susceptor <NUM> is referred to herein as the "conversion efficiency," and is based on a variety of factors, such as bulk resistivity of the metal, dielectric of the metal, metal geometry and heat loss, power supply consistency and efficiency, coil geometry, and losses and overall frequency of operation-to identify some of these factors. The device <NUM> is designed and configured to maximize the conversion efficiency.

To effectuate the heating and conversion to an aerosol of the consumable, the housing <NUM> containing the filter tube <NUM> wrapped around the consumable-containing unit <NUM> is placed inside an aerosol producing device <NUM>, as shown in <FIG>. The aerosol producing device <NUM> comprises a case <NUM> to contain the consumable-containing package <NUM>, the induction heating element <NUM> to heat the susceptor <NUM>, and a controller <NUM> to control the induction heating element <NUM>.

The case <NUM> is designed for ergonomic use. For ease of nomenclature, the case <NUM> is described using terms such as front, back, sides, top and bottom. These terms are not meant to be limiting, but rather, used to describe the positions of various components relative to each other. For purposes of describing the present invention, the front <NUM> will be the portion of the case <NUM> that faces the user when used as intended as described herein. As intended, when the user grasps the case <NUM> for use, the fingers of the user will wrap around the back <NUM> of the device <NUM> with the thumb wrapping around the front <NUM>.

The case <NUM> defines a cavity <NUM> (see <FIG>) in which the components of the device <NUM> are contained. As such, the case <NUM> is designed to contain a substantial portion of the consumable-containing package <NUM>, the controller <NUM>, the inductive heating element <NUM>, and the power source <NUM>. In the preferred embodiment, the top-front portion of the case <NUM> defines an orifice <NUM>. The mouthpiece portion <NUM> of the consumable-containing package <NUM> projects out from the orifice <NUM> so that the user has access to the consumable-containing package <NUM>. The mouthpiece <NUM> projects sufficiently out of the case <NUM> to allow the user to place his or her lips around the mouthpiece <NUM> to inhale the consumable aerosol.

The case <NUM> is intended to be user-friendly and easily carried. In the preferred embodiment, the case <NUM> may have dimensions of approximately <NUM> tall (measured from top <NUM> to bottom <NUM>) by <NUM> deep (measured from front <NUM> to back <NUM>) by <NUM> wide (measured from side <NUM> to side <NUM>). This may be manufactured by proto-molding for higher quality/sturdier plastic parts.

In some embodiments, the consumable-containing package <NUM> may be held in a retractor that allows the consumable-containing package <NUM> to be retracted inside the case <NUM> for storage and travel. Due to the configuration of the consumable-containing package <NUM>, the case <NUM> does not need a clean-out through-hole like other devices in which some combustion is still prevalent creating byproduct residue from the combustion. In embodiments where the consumable-containing package <NUM> comprises a user mouthpiece <NUM> and filter tube <NUM>, if there are any byproducts created during operation they will remain in the disposable consumable-containing package <NUM>, which is changed out when the user inserts a new consumable-containing package <NUM>, and filter tube <NUM> if necessary, into the case <NUM>. Thus, the interior of case <NUM> stays clean during operation.

In the preferred embodiment, the top <NUM> of the case <NUM> comprises a user interface <NUM>. Placing the user interface <NUM> at the top <NUM> of the case <NUM> allows the user to easily check the status of the device <NUM> prior to use. The user could potentially view the user interface <NUM> even while inhaling. The user interface <NUM> may be multi-color LED (RGB) display for device status indication during use. A light-pipe may be used to provide wide angle visibility of this display. By way of example only, user interface <NUM> has a <NUM> inch (diagonal) OLED display with 128x32 format and I2C (or SPI) interface. The user interface <NUM> is capable of haptic feedback <NUM> (vibration) and audio feedback <NUM> (piezo-electric transducer). In some embodiments, a clear plastic (PC or ABS) cover may be placed over the OLED glass to protect it from damage/scratches.

The back <NUM> of the case comprises a trigger <NUM>, which is a finger activated (squeeze) button to turn the device on/initiate "puff. " Preferably, the trigger <NUM> is adjacent to the top <NUM>. In this configuration, the user can hold the case <NUM> as intended with his or her index finger on or near the trigger <NUM> for convenient actuation. In some embodiments, a locking mechanism may be provided on the trigger <NUM> - either mechanically or through electrical interlock that requires the case <NUM> to be opened before the trigger <NUM> is electrically enabled. In some embodiments, a haptic feedback motor <NUM> may be mechanically coupled to the trigger <NUM> to improve recognition of haptic feedback by the user during operation. Actuation of the trigger <NUM> powers the induction heating element <NUM> to heat the susceptor <NUM>.

The device <NUM> is powered by a battery <NUM>. Preferably, the battery <NUM> is a dual cell Li-ion battery pack (series connected) with 4A continuous draw capability, and <NUM>-750mAh rated. The dual cell pack may include protection circuit. The battery <NUM> can be charged with a USB Type "C" connector <NUM>. The USB type "C" connector <NUM> can also be used for communications. The controller <NUM> may also provide for battery voltage monitoring <NUM> for battery state of charge/discharge display.

The trigger <NUM> is operatively connected to the induction coil driver <NUM> via the controller <NUM>. The induction coil driver <NUM> activates the inductive heating element <NUM> to heat the susceptor <NUM>. The present embodiment eliminates the motor driven coil design in the prior art.

The induction coil driver <NUM> can provide drive/multiplexing for multiple coils. For example, the induction coil driver <NUM> may provide drive/multiplexing for <NUM> or more coils. Each coil is wrapped around one segment of the consumable-containing package <NUM> and can be actuated at least one or more times. Therefore, one segment of the consumable-containing package <NUM> can be heated twice, for example. In a device <NUM> having six coils, the user could extract <NUM> "puffs" from the device <NUM>.

The induction coil drive circuit in the preferred embodiment may be directly controlled by a microprocessor controller <NUM>. A special peripheral in this processor (Numerically Controlled Oscillator) allows it to generate the frequency drive waveforms with minimal CPU processing overhead. The induction coil circuit may have one or more parallel connected capacitors, making it a parallel resonant circuit.

The drive circuit may include current monitoring with a "peak detector" that feeds back to an analog input on the processor. The function of the peak detector is to capture the maximum current value for any voltage cycle of the drive circuit providing a stable output voltage for conversion by an analog-to-digital converter (part of the microprocessor chip) and then used in the induction coil drive algorithm.

The induction coil drive algorithm is implemented in firmware running on the microprocessor. The resonant frequency of the induction coil and capacitors will be known with reasonable accuracy by design as follows:
<MAT>.

There will be manufacturing tolerances to the values of L and C (from above), which will produce some variation in the actual resonant frequency versus that which is calculated using the formula above. Additionally, there will be variation in the inductance of the induction coil based on what is located inside of this coil. In particular, the presence of a ferrous metal inside (or in the immediate vicinity) of this coil will result in some amount of inductance change resulting in a small change in the resonant frequency of the L-C circuit.

The firmware algorithm for driving the induction coil will sweep the frequency of operation over the maximum expected frequency range, while simultaneously monitoring the current, looking for the frequency where the current draw is at a minimum. This minimum value will occur at the frequency of resonance. Once this "center frequency" is found, the algorithm will continue to sweep the frequency by a small amount on either side of the center frequency and adjust the value of the center frequency as required to maintain the minimum current value.

The electronics are connected to the controller <NUM>. The controller <NUM> allows for a processor based control of frequency to optimize heating of the susceptor <NUM>. The relationship between frequency and temperature seldom correlates in a direct way, owing in large part to the fact that temperature is the result of frequency, duration and the manner in which the consumable-containing package <NUM> is configured. The controller <NUM> may also provide for current monitoring to determine power delivery, and peak voltage monitoring across the induction coil to establish resonance. By way of example only, the controller may provide a frequency of approximately <NUM> to approximately <NUM>, and preferably, <NUM> with a three-second pre-heat cycle to bring the temperature of the susceptor <NUM> to <NUM> degrees Celsius or higher in one second. In some embodiments, the temperature of the susceptor <NUM> can be raised to <NUM> degrees Celsius or higher in one second. In some embodiments, the temperature can be raised as high as <NUM> degrees Celsius. Thus, the present embodiment has an effective range of <NUM>-<NUM> degrees Celsius. In prior art devices, such temperatures would combust the consumable, making the prior art devices ineffective at these temperatures. In the present invention, such high temperatures can still be used to improve the efficiency of aerosol production and allow for quicker heat times.

The device <NUM> may also comprise a communications system <NUM>. In the preferred embodiment, Bluetooth low energy radio may be used to communicate with a peripheral device. The communications system <NUM> may serial interface to the main processor for communicating information with a phone, for example. Off-the-shelf RF module (pre-certified: FCC, IC, CE, MIC) can also be used. One example utilizes Laird BL652 module because SmartBasic support allows for rapid application development. The communication system <NUM> allows the user to program the device <NUM> to suit personal preferences related to the aerosol density, the amount of flavor released, and the like by controlling the frequency and the <NUM>-stage duty cycle, specifically, the pre-heat stage, heating stage, and wind-down stage of the inductive heating elements <NUM>. The communication system <NUM> may have one or more USB ports <NUM>.

In some embodiments, an RTC (Real-time Clock/Calendar) with battery back-up may be used to monitor usage information. The RTC can measure and store relevant user data to be used in conjunction with an external app downloaded on to a peripheral device, such as a smartphone.

In some embodiments, a micro-USB connector (or USB type C connector or other suitable connector) may be located on the bottom of the case <NUM>. Support connector with plastics may be provided on all sides to reduce stress on connector due to cable forces.

By way of example only, the device <NUM> may be used as follows. Power for the device may be turned on from momentary actuation of the trigger <NUM>. For example, a short press of the trigger (<<NUM> sec) may turn the device <NUM> on but does not initiate the heating cycle. A second short press of the trigger <NUM> (<<NUM> sec) during this time will keep the device <NUM> on for a longer period of time and initiate Bluetooth advertising if no active (bonded) Bluetooth connection with phone currently exists. A longer press of the trigger <NUM> (><NUM> sec) initiates the heating cycle. The power for the device <NUM> may remain on for a short period of time after each heating cycle (e.g., <NUM> sec) to display updated unit status on the OLED user interface <NUM> before powering off. In some embodiments, the device <NUM> may power on when the consumable-containing package <NUM> is deployed from the case <NUM>. In some embodiments, a separate power switch <NUM> may be used to turn the device on and off.

When an active connection is found with a smartphone and the custom application is running on the smartphone, then the device <NUM> will remain powered on for up to <NUM> minutes before powering off. When the battery level is too low to operate, the user interface display <NUM> flashes several times (showing battery icon at "<NUM>%" level) before turning unit off.

In some embodiments, the user interface <NUM> may display a segmented cigarette showing which segments remain (solid fill) versus which segments have been used (dotted outline) as an indicator of how much of the consumable-containing package <NUM> still contains consumable products to be released. The user interface <NUM> can also display a battery icon updated with current battery status, charging icon (lightning bolt) when the device is plugged in, and a Bluetooth icon when active connection exists with a smartphone. The user interface <NUM> may show the Bluetooth icon flashing slowly when no connection exists but the device <NUM> is advertising.

The device may also have an indicator <NUM> to inform the user of the power status. The indicator <NUM> may be an RGB LED. By way of example only, the RGB LED can show a green LED on when the device is first powered on, a red LED flashing during the preheat time, a red LED on (solid) during the "inhale" time, and a blue LED flashing during charging. Duty cycle of flashing indicates the battery's relative state of charge (<NUM>-<NUM>%) in <NUM>% increments (solid blue means fully charged). A fast flashing of blue LED may be presented when an active Bluetooth connection is detected (phone linked to device and custom app on phone is running).

Haptic feedback can provide additional information to the user during use. For example, <NUM> short pulses can be signaled immediately when power is turned on (from finger trigger button). An extended pulse at the end of preheat cycle can be signaled to indicate the devices refer inhalation (start of HNB "inhale" cycle). A short pulse can be signaled when USB power is first connected or removed. A short pulse can be signaled when an active Bluetooth connection is established with an active phone app running on the smartphone.

A Bluetooth connection can be initiated after power is turned on from a short (<<NUM> sec) press of the finger grip button. If no "bonded" BLE (Bluetooth Low Energy) connection exists, that the devices may begin slow advertising ("pairing" mode) once a second short press is detected after initial short press is detected that powers the device on. Once a connection is established with the smartphone application, the Bluetooth icon on the user interface display <NUM> may stop flashing and the blue LED will turn on (solid). If the device <NUM> is powered on and it has a "bonded" connection with a smartphone, then it may begin advertising to attempt to re-establish this connection with the phone up until it powers off. If the connection with this smartphone is able to be re-established, then the unit may remain powered on for up to <NUM> minutes before powering itself off. To delete a bonded connection, the user can power the device on with a short press followed by another short press. While BLE icon is flashing, the user can press and hold the trigger <NUM> until the device <NUM> vibrates and the Bluetooth icon disappears.

So, by tight control of the afore-mentioned conversion efficiency factors and the product consistency factors, it is possible to provide controlled delivery of heat to the consumable-containing unit <NUM>. This controlled delivery of heat involves a microprocessor controller <NUM> for the monitoring of the induction heating system <NUM> to maintain various levels of electrical power delivery to the susceptor <NUM> over controlled intervals of time. These properties enable a user-control feature that would allow the selection of certain consumable flavors as determined by the temperature at which the consumable aerosol is produced.

In some embodiments a microprocessor or configurable logic block can be used to control the frequency and power delivery of the induction heating system. As shown in <FIG>, an induction heating system <NUM> may comprise a wire coil <NUM> in parallel with one or more capacitors <NUM> to and from a self-resonant oscillator. The inductance of the coil <NUM> in combination with the capacitance of the capacitor(s) <NUM> largely defines the resonant frequency at which the circuit will operate. In this embodiment, however, a microprocessor/microcontroller <NUM> can instead be used to drive the power switches and hence control the frequency of oscillation of the circuit. With this approach, the peak voltage and current are used as feedback to allow the microprocessor control program to provide closed tuning to find resonance. The benefit of this approach is that it allows efficient control of the power delivered to the susceptor by synchronously switching the oscillation of the circuit on and off under the control of the microprocessor <NUM> control program and provides optimal on/off switching of the power control elements driving the induction coil system.

Based on these concepts, a number of variations have been contemplated by the inventors. Thus, as discussed above, the present invention comprises a consumable-containing unit <NUM>, a susceptor <NUM> embedded within the consumable-containing unit <NUM>, a heating element <NUM> configured to at least partially surround the consumable-containing unit <NUM>, a controller <NUM> to control the heating element <NUM>, and a case <NUM> to contain the consumable-containing unit <NUM>, the susceptor <NUM>, the heating element <NUM>, and the controller <NUM>. Preferably, the consumable-containing unit <NUM> is contained with the susceptor <NUM> in a consumable-containing package <NUM>. As such, any description of the relationships between the consumable-containing package <NUM> with other components of the invention may also apply to the consumable-containing unit <NUM>, as some embodiments may not necessarily require packaging of the consumable-containing unit <NUM>.

In some embodiments, as shown in <FIG>, the device comprises a self-resonant oscillator for controlling the inductive heating element <NUM>. The self-resonant oscillator comprises a capacitor <NUM> operatively connected to the inductive heating element <NUM> in parallel. In some embodiments, as shown in <FIG>, multiple heating elements <NUM> may be connected in parallel with their respective capacitors 260a, 260b. Preferably, the heating elements are in the form of a coiled wire 162a, 162b.

To allow a single consumable-containing package <NUM> to generate aerosol multiple times, multiple heating elements <NUM> and/or moveable heating elements <NUM> may be used. Thus, the heating element <NUM> comprises a plurality of coiled wires 162a, b, where each coiled wire may be operatively connected to the controller <NUM> for activation independent of the other coiled wires.

In some embodiments, the heating element <NUM> may be moveable. In such embodiments, the consumable-containing package <NUM> may be an elongated member defining a first longitudinal axis L, and the heating element may <NUM> be configured to move axially along the first longitudinal axis L. For example, as shown in <FIG>, the heating element <NUM> may be attached to a carrier <NUM>. The carrier <NUM> may be operatively connected to the housing <NUM> so as to move along the length of the consumable-containing package <NUM> while the heating element <NUM> remains coiled around the consumable-containing package <NUM>. The span S of the coil (measured as the linear distance from the first turn <NUM> of the coil to the last turn of the coil <NUM>) may be short enough only to cover a segment of the consumable-containing package <NUM>. Once the heating element <NUM> has been activated at that segment, the carrier <NUM> advances along the consumable-containing package <NUM> along its longitudinal axis L to another segment of the consumable-containing package <NUM>. The distance of travel of the carrier <NUM> is such that the first turn <NUM> of the coil stops adjacent to where the last turn <NUM> of the coil had previously resided. Thus, a new segment of equal size to the previously heated segment is ready to be heated. This can continue until the carrier <NUM> moves from the first end <NUM> of the consumable-containing package <NUM> to the opposite end <NUM>.

In embodiments in which the consumable-containing package <NUM> contains multiple consumable-containing units <NUM>, the span S of the coil, may be approximately the same size as the length of the consumable-containing unit <NUM>. The carrier <NUM> may be configured to align the coil with a consumable-containing unit <NUM> so that the coil can heat an entire consumable-containing unit <NUM>. The carrier <NUM> may be configured to move the coil from one consumable-containing unit <NUM> to the next, again allowing a single consumable-containing package <NUM> to be heated multiple times with the aerosol being released each time.

As shown in <FIG>, to facilitate proper alignment of the heating element <NUM> around the consumable-containing package <NUM>, the device <NUM> may comprise a package aligner. For example, the package aligner may be a magnet <NUM>. Preferably, the magnet <NUM> is a cylindrical magnet defining a second longitudinal axis M. In embodiments in which the heating element <NUM> is a cylindrical coil wrapped around the consumable-containing package <NUM>, the cylindrical coil defines a third longitudinal axis C. The cylindrical magnet <NUM> and the heating element <NUM> are configured to maintain collinear alignment of the second longitudinal axis M with the third longitudinal axis C. Preferably, the cylindrical magnet <NUM> is a round ring magnet, where the center is a path for air flow. Preferably, any magnet <NUM> would be a rare earth neodymium type. It would be axially magnetized.

In the embodiment using a magnet <NUM> for alignment, one end <NUM> of the consumable-containing package <NUM> may comprise a magnetically attractive element <NUM>. Preferably, the magnetically attractive element <NUM> is a stamped ferrous sheet metal component that is manufactured into the first end <NUM> of the consumable-containing package <NUM>. The cylindrical magnet <NUM> could be part of the aerosol producing device <NUM> and the consumable-containing package <NUM> could have a magnetically attractive element <NUM> or washer attached to its end <NUM> so that the consumable-containing package <NUM> is pulled onto the magnet <NUM> affixed to the aerosol producing device <NUM>. Other combinations of magnets <NUM> and magnetically-attractive elements <NUM>, in various positions, may be used to accomplish the desired alignment.

In some embodiments, preferably one that uses a consumable-containing package <NUM> with a filter tube <NUM> and a housing <NUM>, the package aligner may be a receiver <NUM>, such as a closely-fitting cylinder (if the housing <NUM> is cylindrical) that may be used to align the consumable-containing package <NUM>, and the coil <NUM> could be positioned outside the receiver <NUM>, as shown in <FIG>. Preferably, the receiver <NUM> would be made of non-conductive material to avoid induction heating, such as borosilicate glass, quartz glass, Pyroceram glass, Robax glass, high-temperature plastics such as Vespel, Torlon, polyimide, PTFE (polytetrafluoroethylene), PEEK (polyetheretherketone), or other suitable materials. Alternatively, the cylinder could be made of a conductive material that has a lower resistivity than the susceptor <NUM> in the consumable-containing package <NUM>, which would allow some induction heating of the receiver <NUM>, but not as much as the susceptor <NUM>. Examples of lower-resistive materials may include copper, aluminum, and brass, where the susceptor <NUM> is made of higher-resistance materials such as iron, steel, tin, carbon, or tungsten, although other materials may be used. In some embodiments, a receiver <NUM> with an equal or higher resistivity than the susceptor <NUM> may be used, which will heat the outside of the consumable-containing package <NUM> as the receiver <NUM> heats up via induction. The receiver <NUM> can be fixed to the device <NUM> and aligned properly with the coils <NUM> such than when the consumable-containing package <NUM> is inserted into the coils <NUM>, the susceptor <NUM> is properly aligned with the coils <NUM>.

In some embodiments, the housing <NUM> may function as the receiver. Therefore, rather than a separate receiver <NUM>, the housing <NUM> may have the characteristics described above and insertion into the coils <NUM> may function as the alignment process, or the housing can be fixed within the coils <NUM> and the filter tube <NUM> containing the consumable-containing unit <NUM> and the susceptor <NUM> can be inserted into the housing <NUM>.

In some embodiments, multiple activations of a single consumable-containing package can be accomplished with a susceptor <NUM> having multiple prongs <NUM> as shown in <FIG>. A multi-pronged susceptor is a susceptor <NUM> with two or more prongs <NUM>. In some embodiments, the susceptor may have three prongs 290a, 290b, 290c. In some embodiments, the susceptor <NUM> may have four prongs. In some embodiments, the susceptor <NUM> may have more than four prongs. In the preferred embodiment, the multi-pronged susceptor <NUM> has three or four prongs.

The multiple prongs 290a, 290b, 290c of the multi-pronged susceptor <NUM> are generally parallel to each other as shown in <FIG>. The multi-pronged susceptor <NUM> is configured and may be embedded into the consumable-containing package <NUM> in such a way that each prong 290a, 290b, 290c is parallel to and equally spaced from the longitudinal axis of the consumable-containing package L, and equally spaced apart from each other along the perimeter of an imaginary circle. As such, when viewed in cross-section, as shown in <FIG>, the susceptor prongs 290a, 290b, 290c are equally spaced apart from each other about the circular face of the consumable-containing package <NUM>. Such arrangement allows each prong 290a, 290b, 290c to maximize non-overlapping heating zones for each prong, when each prong is maximally activated. In other words, when a susceptor prong 290a, 290b, 290c is heated, it will radiate heat radially away from the susceptor prong 290a, 290b, 290c creating a circular heating zone with the susceptor prong 290a, 290b, 290c in the center. Each susceptor prong 290a, 290b, 290c will heat its own circular zone, although some overlap may be inevitable. Collectively, an entire cross-sectional area of a consumable-containing unit <NUM> can be heated, one cross-sectional segment at a time.

When the heating element <NUM> is a cylindrical coil wrapped around a susceptor <NUM>, the maximum amount of energy is transferred to the center of the cylindrical coil. Therefore, when the susceptor <NUM> is aligned with the center of the cylindrical coil, the susceptor <NUM> will receive the maximum amount of energy from the electricity passing through the coil. In other words, when the susceptor prong 290a, 290b, 290c is collinear with the cylindrical coil, the susceptor prong 290a, 290b, 290c will receive the maximum amount of energy from the cylindrical coil. Thus, to heat each susceptor prong 290a, 290b, 290c independently, the susceptor prong 290a, 290b, 290c and the center of the coil must be moved relative to each other so that the center of the coil aligns with one of the susceptor prongs 290a, 290b, 290c in sequence. This can be accomplished by moving the susceptor prong relative to the coil, or by moving the coil relative to the susceptor prong, or both.

In the preferred embodiment, the heating element <NUM> moves relative to the susceptor <NUM>. For example, the cylindrical coil may be wrapped around the consumable-containing package <NUM> and configured to rotate along an eccentric path so that during one rotation of the cylindrical coil each of the prongs 290a, 290b, 290c will align with the center of the coil at different times as shown in <FIG>. The consumable-containing package <NUM> may be an elongated member defining a first longitudinal axis L, wherein the heating element <NUM> is a coil wrapped around the consumable-containing package <NUM> to form a cylinder defining a second longitudinal axis C, and wherein the heating element <NUM> is configured to rotate about the consumable-containing package <NUM> in an eccentric path such that the second longitudinal axis C aligns collinearly with each of the prongs 290a, 290b, 290c of the multi-pronged susceptor at some point during the movement of the heating element about the consumable-containing package <NUM>. Therefore, the multi-prong susceptor <NUM> is stationary and the coil moves rotationally in an eccentric path so that coil center aligns with the linear axis of each susceptor prong 290a, 290b, 290c, in turn, through the rotation. Electrical slip rings would provide energy to an eccentric path rotating coil design.

Rotation of the heating element <NUM> can be effectuated by a series of gears 300a, 300b operatively connected to a motor <NUM>. For example, as shown in <FIG>, the heating element <NUM> may be mounted on a first gear 300a so that the heating element can rotate with the first gear 300a. A second gear 300b can be operatively connected to the first gear 300a such that rotation of the second gear 300b causes rotation of the first gear 300a. The second gear 300b may be operatively connected to a motor <NUM> to cause the second gear 300b to rotate. The heating element <NUM> is mounted to the first gear 300a in such a manner that rotation of the first gear 300a causes the longitudinal axis C of the heating element <NUM> to move along an eccentric path rather than causing the heating element to rotate about a fixed, non-moving center. Thus, the center of the heating element <NUM> can shift to align with the different prongs 290a, 290b, 290c.

In some embodiments, the heating element <NUM>, the gears 300a, 300b, and the motor <NUM> may be mounted on a carrier <NUM> as shown in <FIG>. The carrier <NUM> allows the heating element, gears 300a, 300b and the motor <NUM> to move axially along the length of the consumable-containing package <NUM>. The carrier <NUM> may be operatively connected to a driver <NUM>, which is operatively connected to a second motor <NUM>. For example, the driver <NUM> may be threaded. The carrier <NUM> may have a threaded hole <NUM> through which the driver <NUM> is inserted. Activation of the second motor <NUM> causes the driver <NUM> to rotate. Rotation of the driver <NUM> causes the carrier <NUM> to move along the driver <NUM> as shown by the double arrow in <FIG>.

In some embodiments, rather than having the heating element <NUM> rotate along an eccentric path, the heating element <NUM> can be moved translationally along the X-Y axis when viewed in cross section. Therefore, the consumable-containing package <NUM> may be an elongated member defining a longitudinal axis L, and wherein the heating element <NUM> is configured to move radially relative to the longitudinal axis L when viewed in cross-section to align the center of the cylindrical, coiled heating element <NUM> with each of the prongs 290a, 290b, 290c of the multi-pronged susceptor <NUM>, in turn. In the X-Y axis positioning scenario the coil energy could be supplied through a flexible electrical conductor or by moving electrical contacts.

For example, the heating element <NUM> may be operatively mounted on a pair of translational plates <NUM>, <NUM> as shown in <FIG>. Specifically, the heating element <NUM> may be mounted directly on a first translational plate <NUM>, and the first translational plate <NUM> may be mounted on a second translational plate <NUM>. The first translational plate <NUM> may be configured to move in the X or Y direction, and the second translational plate <NUM> may be configured to move in the Y or X direction, respectively. In the example shown in <FIG>, the first translational plate <NUM> is configured to move in the X direction, while the second translational plate <NUM> is configured to move in the Y direction. This configuration can be switched so that the first translational plate <NUM> is configured to move in the Y direction and the second translational plate <NUM> is configured to move in the X direction. The first and second translational plates <NUM>, <NUM> may be operatively connected to their respective motors, for example, via gears, to cause the translational plates to move in the appropriate direction. Between the two translational plates <NUM>, <NUM>, the heating element <NUM> can be moved so that its longitudinal axis C can align collinearly with any of the prongs 290a, 290b, 290c.

In other arrangements the coil assembly could move along the susceptor's linear axis, independent of a rotation or non-rotation movement mechanisms as discussed above. Therefore, a three pronged susceptor would allow the device to heat a consumable-containing package <NUM> three times at the same linear position by heating the three different prongs 290a, 290b, 290c three different times before it moves to its next linear position, where it will be able to heat three times again. In a consumable-containing package <NUM> having four linear positions, one consumable-containing package should be able to provide <NUM> distinct "puffs," i.e. <NUM> prongs times <NUM> positions along the length of the consumable-containing package <NUM>.

In some embodiments, rather than having the heating element <NUM> move relative to the consumable-containing package <NUM>, the consumable-containing package <NUM> can be moved relative to the heating element. Therefore, the consumable-containing package <NUM> is configured to rotate within the heating element <NUM> in an eccentric path such that the second longitudinal axis C defined by the coils aligns collinearly with each of the prongs 290a, 290b, 290c of the multi-pronged susceptor at some point during the rotation of the consumable-containing package <NUM> within the heating element <NUM>. Alternatively, the consumable-containing package <NUM> is configured to move radially within the heating element <NUM> such that the second longitudinal axis C aligns collinearly with each of the prongs of the multi-pronged susceptor at some point during the movement of the consumable-containing package <NUM> within the heating element <NUM>. In some embodiments, both the consumable-containing package <NUM> and the heating element <NUM> may move. For example, the heating element <NUM> may move linearly along the longitudinal axis of the consumable-containing package <NUM>, and the consumable-containing package <NUM> can move in an eccentric or radial path to move the susceptor <NUM> into position relative to the heating element <NUM>, so that all of the consumables are heated sequentially as the user takes individual puffs. Other variations of movement may also be used.

The movement mechanisms described above are merely examples. The mechanism in an X-Y-Z movement scenario could be accomplished using a variety of combinations of motors, linear actuators, gears, belts, cams, solenoids, and the like.

With reference to <FIG>, a closed loop control of the induction heating system can be based on sensing of a magnetic flux density created by the induction heating system. Induction heating systems operate by virtue of creating a concentrated, alternating magnetic field inside of the induction coil heating element. This field will produce a heating effect in a metal susceptor by virtue of the eddy currents and magnetic flux reversal (assuming a ferrous receptor material) that occur in the susceptor material. Induction heating is typically "open loop" in that there are limited means of monitoring of the temperature of the susceptor inside of the induction coil while it is operating. Under controlled conditions, the magnetic field external to the induction coil and in reasonable proximity to the coil can be used determine the intensity of the flux inside of the coil. For example, a small coil <NUM> can be placed in reasonable proximity to the induction coil-type heating element <NUM> with its axis approximately parallel to the magnetic flux field lines <NUM> passing through the small coil <NUM>, providing a means of detection of the magnitude of the magnetic flux of the induction coil-type heating element <NUM> present by virtue of the voltage induced across the small coil <NUM> due to the changing magnetic flux passing through the small coil <NUM>. The magnitude of this external flux can then be calibrated to correlate to the magnetic flux density inside of the heating element <NUM>, and therefore, be used as a means of closed loop control of the induction system to ensure consistent performance insofar as heating of the susceptor <NUM>. The magnetic flux is symmetrical around the axis of the induction coil. A measurement of the flux density taken any place near the induction coil can be used to extrapolate the magnetic flux density inside of the heating element, based on characterization of the relative magnitudes of the magnetic flux in each location (inside of the induction coil and inside of the parasitic sensing coil). In practice, there is no need to quantify this, as the flux sensing is instead used to infer the rate of heating that will occur in a susceptor <NUM> that is present in this magnetic field. Thus, the small coil <NUM> configured in this way functions as a magnetic flux sensor.

Therefore, in some embodiments, the device may further comprise a magnetic flux sensor adjacent to the inductive heating element <NUM> and configured to measure a magnetic flux created by the inductive heating element <NUM>. The magnetic flux sensor may be operatively connected to the controller <NUM> to control activation of the inductive heating element <NUM> based on feedback from the magnetic flux sensor.

In some embodiments, it is desirable to be able to detect whether a consumable-containing unit <NUM>, or a portion thereof, has been heated or not. If a consumable-containing unit <NUM> has already been heated, then the heating element <NUM> can heat the next consumable-containing unit <NUM> or the next segment of a consumable-containing unit <NUM> so as to prevent energy from being wasted on a used portion of the consumable-containing unit <NUM>. Therefore, in some embodiments, as shown in <FIG>, a method of detecting the segments of the consumable-containing package <NUM> that have been used is provided in the device, allowing the device to autonomously determine the next unused segment that is available for use. For example, the device may comprise a use sensor <NUM> to detect whether a portion of the consumable-containing package <NUM> being sensed had been heated beyond a predetermined temperature. In some embodiments, the use sensor <NUM> may detect visual changes in the consumable-containing package <NUM> that is indicative of heating. In some embodiments, the use sensor <NUM> may detect thermal changes in the consumable-containing package <NUM> that is indicative of heating. In some embodiments, the use sensor <NUM> may detect textural changes (i.e. changes in the texture) in the consumable-containing package <NUM> that is indicative of heating. In some embodiments, the use sensor <NUM> may be the controller keeping track of where the heating element <NUM> is along the consumable-containing package <NUM> and when it has been heated relative to its movement along the consumable-containing package <NUM>. For example, the controller may comprise a memory for storing locations of the portions of the consumable-containing package <NUM> that have been heated to the predetermined temperature.

In the preferred embodiment, the use sensor <NUM> is a photoreflective sensor. The photoreflective sensor may be configured to detect changes in the consumable-containing package <NUM> from its original state compared to a state when the consumable-containing package <NUM> has been exposed to significant heat (i.e. beyond normal temperatures of the day). More preferably, the consumable-containing package <NUM> may be comprised of a thermal sensitive dye that changes colors when heated to a predetermined temperature. Such change in color may be detectable by the photoreflective sensor.

The thermally sensitive dye may be printed around the exterior surface of the consumable-containing package <NUM>. When a segment of the consumable-containing package <NUM> is heated, a band <NUM> in closest proximity to the heated segment changes colors. For example, the band <NUM> may change from white to black. The use sensor <NUM> mounted with the heating element <NUM> has optics <NUM> focused just above-or below-the heating element to provide a side view of the consumable-containing package <NUM> over the full range of the moving heating element <NUM>.

In some embodiments, a limit switch <NUM> is also installed at one end <NUM> of the consumable-containing package <NUM> and used to detect when the consumable-containing package <NUM> is removed or reinserted into the device. When a consumable-containing package <NUM> has been re-inserted, the device activates the motorized heating element assembly and moves it across its full range of travel, allowing the use sensor <NUM> to detect if any segments have been previously heated, by detecting the dark bands <NUM> of the thermally sensitive dye. Thus, the device may further comprise a limit switch <NUM> to reset the memory when a new consumable-containing package <NUM> is inserted into the housing.

In some embodiments, to manage the thermal heat dissipation from the heating element <NUM>, the device may further comprise a heat sink <NUM> operatively connected to the inductive heating element <NUM>. Induction heating involves the circulation of high currents in the induction coil, resulting in resistive heating in the wire used to form the coil. Thermal heat dissipation takes advantage of materials with high thermal conductivity that are electrically insulating to form heat sinks <NUM>. Preferably, heat sinks <NUM> can be formed either through injection molding or potting processes. Because the preferred embodiment utilizes a cylindrical coil as the heating element <NUM>, the heat sink <NUM> may also be a cylinder formed around the induction coil, so that it encapsulates the coil as shown in <FIG>. The cylindrical heat sink <NUM> encapsulating the heating element <NUM> resides within a vertical cavity inside the case <NUM>, forming a sort of "chimney" within which air convection occurs. The chimney requires venting at the top to support the airflow. This method also eliminates fringing of the electromagnetic field, allowing for a very focused heating method on each segment of the consumable-containing package <NUM>. As a result of such focus, it would not be necessary to wrap the consumable-containing unit <NUM> inside the consumable-containing package <NUM> in a non-conductive foil or other similar material, paper or a similar material would suffice.

In the preferred embodiment, the heat sink <NUM> is a finned cylinder encompassing the inductive heating element <NUM>. The finned cylinder is a cylindrically shaped heat sink with fins <NUM> projecting laterally away from its exterior surface <NUM>. Preferably each fin <NUM> extends substantially the length of the cylinder to provide a substantial surface area from which heat from the heating element <NUM> can dissipate. The thermally conductive material of the heat sink <NUM> may be a polymer. Thermally conductive polymer may be a thermoset, thermoplastic molding or potting compound. The heat sink <NUM> may be machined, molded or formed from these materials. Material could be rigid or elastomeric. Some examples of the thermally conductive compounds used in thermally conductive polymers are aluminum nitride, boron nitride, carbon, graphite and ceramics. In the preferred embodiment, the heating element <NUM> is an inductive coil wrapped in a finned cylinder of a thermally conductive polymer that has been molded around the coil, with an open center creating venting via a chimney-like effect.

In some embodiments, as shown in <FIG>, the device may further comprise an airflow controller <NUM> to provide a means for adjusting the flavor robustness of the consumable-containing unit <NUM> by controlling the airflow that is drawn through the consumable-containing package <NUM>. The design of the consumable-containing package <NUM> is such that the amount of vapor/flavor that is introduced into the airflow passageways is a function of the duration and intensity of induction heating, and the air pressure differential between the air passageway(s) through the consumable-containing package <NUM>. This pressure differential draws the vapor out of the consumable-containing package <NUM> and into the airflow. If the airflow into the first end <NUM> of the consumable-containing package <NUM> can be controlled, this pressure differential can be varied, allowing more (or less) vapor to be introduced into the airflow, effectively altering the robustness of the flavor. This ability to alter the flavor robustness is closely integrated with the heating of the consumable-containing package <NUM>, as it is the rise in temperature of the consumable that produces this vapor. By precise control of the heating process (time and rate) and the airflow through the first end <NUM> of the consumable-containing package <NUM>, wide range of flavor robustness experiences can be produced.

For example, the airflow controller <NUM> may comprise an adjustable flow control valve <NUM>, such as a needle valve, butterfly valve, ball valve, or an adjustable aperture. Adjustable flow control valves allow the user to control the airflow even during use. However, the airflow controller <NUM> may also be a membrane <NUM> with fixed apertures, such as a porous or fibrous membrane or element. A membrane <NUM> may also act as an intake particulate filter. Therefore, flow control mechanisms may or may not be user adjustable. In the membrane <NUM> embodiments, there may be provided multiple membranes <NUM> with different sized apertures. Thus, the user can select the desired aperture size and apply that membrane <NUM> to the first end <NUM> of the device. If the user prefers increased or decreased airflow, the user can select another membrane <NUM> with larger or smaller apertures, respectively. In some embodiments, the airflow controller <NUM> may use both a control valve <NUM> and a membrane <NUM>. For example, the membrane <NUM> may be precede the control valve <NUM> so as to control airflow and filter particulates before the control valve <NUM>, then the control valve <NUM> can further control the airflow for fine-tuned control of the airflow.

In some embodiments, rather than having the aerosol flow from the consumable-containing unit <NUM> through openings <NUM> of the encasement <NUM> into a filter tube <NUM>, and towards the mouthpiece <NUM>, the air flows into the susceptor <NUM>, draws out the active from the consumable-containing unit <NUM> to create the aerosol that flows through the susceptor <NUM> towards the mouthpiece <NUM>, as shown in <FIG>. In such, embodiments, the susceptor <NUM> may have one or more hollow prongs <NUM> with at least one inlet <NUM> along the length of the each prong <NUM>, and at least one outlet <NUM>. The prong <NUM> comprises a connected end <NUM> operatively connected to a susceptor base <NUM>, and a free end <NUM> opposite the susceptor base <NUM>. The hollow prong <NUM> is connected to the susceptor base <NUM> at the connected end <NUM>. The outlet <NUM> of the hollow prong <NUM> is located towards the free end <NUM>. For example, the outlet may be at the tip <NUM> of the free end <NUM>, or there may be a plurality of outlets <NUM> angularly spaced apart around the perimeter surface of the hollow prong <NUM> at the free end <NUM> side.

In some embodiments, the tip <NUM> of the free end <NUM> may be pointed or sharp to facilitate penetration into the consumable-containing unit <NUM>. The particle size, density, binders, fillers or any component used in the consumable-containing unit <NUM> may be engineered to allow the penetration of the susceptor prongs <NUM>, <NUM> and/or perforation needles without causing excessive compression or changes to the density of consumable-containing unit <NUM>. Changes to the density from compression "packing" of consumable containing unit <NUM> could negatively effect air or vapor flow through the consumable-containing unit <NUM>.

Any consumable particulate that may be pushed thorough the encasement <NUM> after susceptor <NUM> penetration would be held captive in the cavity <NUM> between consumable-containing unit <NUM> and mouthpiece <NUM>. Since tips <NUM> of the prongs <NUM>, <NUM> are sharp it is unlikely that consumable will be ejected out from the encasement <NUM>.

In some embodiments, the outlets <NUM> and/or the inlets <NUM> may be covered with the coating that melts away at heated temperatures. In the preferred embodiment, the consumable-containing unit <NUM> is long enough to cover the entire hollow prong <NUM> except for the outlet <NUM>.

The susceptor base <NUM> may comprise an opening <NUM> that corresponds with the hollow prong <NUM>. In embodiments with multiple hollow prongs 350a-d, each hollow prong 350a-d has its own corresponding opening <NUM>.

In some embodiments, there may be multiple hollow prongs 350a-d. The hollow prongs 350a-d may be arranged in a circle making it compatible with the moving heating element <NUM> or moving consumable-containing package <NUM>. In some embodiments, there may be a single hollow prong <NUM> with the hollow prong <NUM> centered in the susceptor base <NUM>. In some embodiments, there may be a center hollow prong <NUM> surrounded by a plurality of hollow prongs 350a-d. Other hollow prong <NUM> arrangement can be used.

Each hollow prong <NUM> may have at least one inlet <NUM> and at least one outlet <NUM>. Preferably, the hollow prong <NUM> comprises a plurality of inlets <NUM> and a plurality of outlets <NUM>. The inlets <NUM> may be arranged in a series along the length of the hollow prong <NUM>. In some embodiments, the inlets <NUM> may be circularly arranged about the perimeter of the hollow prong <NUM>. Increasing the number of inlets <NUM> on a hollow prong <NUM> increases the number of points through which the aerosol generated can escape from the consumable-containing unit <NUM> and out of the consumable-containing package <NUM>. Similarly, there may be a plurality of outlets <NUM> circularly arranged about the perimeter of a prong <NUM> at the free end <NUM> side.

In some embodiments, the consumable-containing unit <NUM> does not extend from one end <NUM> of the consumable-containing package <NUM> to the mouthpiece <NUM>. As such, a cavity <NUM> exists in between the consumable-containing unit <NUM> and the mouthpiece <NUM>. This cavity <NUM> can be filled with thermally conductive material, flavoring, and the like.

As shown in the cross-sectional view of <FIG>, in use, the susceptor <NUM> is embedded in the consumable-containing unit <NUM>. When the susceptor <NUM> is heated via inductive heating by the heating element <NUM>, the consumable-containing unit releases the aerosol. As the user sucks on the mouthpiece <NUM>, the pressure differential inside the consumable-containing package <NUM> causes the aerosol to enter into the hollow prong <NUM> through the inlet <NUM> and exit through the outlet <NUM> (see arrows showing airflow). The aerosol then enters the cavity <NUM> of the consumable-containing package <NUM> and is filtered through the mouthpiece <NUM> for inhalation by the user. As such, the encasement <NUM> need not have any openings <NUM>.

In some embodiments, as shown in <FIG>, there may be a single hollow prong <NUM> centrally positioned on the susceptor base <NUM>, with a plurality of prongs 290a-d surrounding the hollow prong <NUM>. In such an embodiment, the hollow prong <NUM> need not be capable of heating via induction heating, although it can be. In this embodiment, the consumable-containing unit <NUM> may have a central hole <NUM> through which the hollow prong <NUM> can be inserted for a tight fit.

As shown in <FIG>, in use, when the susceptor prongs <NUM> are heated, the aerosol generated enters through the inlets <NUM> of the hollow prong <NUM> and exits through the outlets <NUM> and into the mouthpiece <NUM> as shown by the airflow arrows.

Aerosol produced by the methods and devices described herein is efficient and reduces the amount of toxic byproducts seen in traditional cigarettes and other heat-not-burn devices.

As shown in <FIG>, testing was conducted on consumable-containing packages <NUM> that were prepared by compressing powdered tobacco mixed with an humectant and PGA, to form the consumable unit <NUM>, around a susceptor <NUM>, encased in a foil covering as the encasement <NUM>, inserted into a filter tube <NUM> in such a way that openings <NUM> were present on three sides as air channels, covered in standard cigarette paper as the housing <NUM>, capped on one end with a high flow proximal filter as the mouthpiece <NUM> and on the other end with a distal filter tip as the end cap <NUM>. The susceptor <NUM> is in the form of a metal sheet twisted into a spiral. The consumable-containing unit <NUM> and the encasement <NUM> have triangular cross-sections. The filter tube <NUM> is a spiral paper tube.

The testing in Durham, North Carolina was done with a prototype device that was determined to have heated the susceptor to 611C (Degrees Centigrade) by virtue of calibrating the electrical power that was used in the testing process.

The Durham test was conducted using a SM459 <NUM>-port linear analytical smoking machine and was performed by technicians familiar with the equipment and all associated accessories. Technicians placed three consumable-containing packages <NUM> in the smoking machine. Each consumable-containing package <NUM> was then "puffed" <NUM> times for a total of <NUM> puffs. The resulting aerosol was then collected on filter pads. The "smoking" regimen was a puff every <NUM> seconds with <NUM>-second puff duration and a volume of <NUM> collected using a bell curve profile. The analysis of the collected aerosol determined that <NUM> of carbon monoxide (CO) was present in the aerosol of each consumable stick, well below the levels at which it could be assumed that combustion has occurred, despite the fact that it is generally assumed that combustion will occur at temperatures greater than 350C.

A second set of tests was conducted in Richmond, Virginia. The Richmond tests were done with a similarly configured consumable-containing package <NUM> and a prototype device that was calibrated to heat a susceptor <NUM> at three separate settings of 275C, 350C and 425C. CO data was generated by Enthalpy Analytical (EA) (Richmond, Virginia, USA), LLC in accordance with EA Method AM-<NUM>. Consumable-containing packages <NUM> were smoked using an analytical smoking machine following the established, Canadian Intense smoking procedure. The vapor phase of the smoke (i.e. aerosol) was collected in gas sampling bags attached to the smoking machine configured to the requested puffing parameters. A non-dispersive infrared absorption method (NDIR) is used to measure the CO concentration in the vapor phase in percent by volume (percent vol). Using the number of consumable-containing packages <NUM>, the puff count, the puff volume, and ambient conditions, the percent CO was converted to milligrams per consumable-containing package (mg/cig).

At the calibrated temperature settings it was determined that no CO was found to be in the aerosol produced at each of the settings, despite the fact that it is generally assumed that combustion will occur at temperatures greater than 350C.

The tests conducted are industry standard tests. In similar industry standard tests, commercially available heat-not-burn products report CO at <NUM>/cig. Standard combustible cigarette reports CO at <NUM>/cig.

Claim 1:
A device (<NUM>) for generating aerosol, comprising:
a. a consumable-containing unit (<NUM>) comprising compressed powder;
b. a susceptor (<NUM>) embedded within the consumable-containing unit (<NUM>), wherein the consumable-containing unit (<NUM>) is compressed about the susceptor (<NUM>);
c. an inductive heating element (<NUM>) configured to at least partially surround the consumable-containing unit (<NUM>);
d. a controller (<NUM>) to control the inductive heating element (<NUM>); and
e. a case (<NUM>) to contain the consumable-containing unit (<NUM>), the susceptor (<NUM>), the inductive heating element (<NUM>), and the controller (<NUM>).