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

<CIT> discloses various configurations of heater components for aerosol provision devices. One heater component is configured to receive aerosol generating material and has a longitudinal axis. The heater component has a first length along the longitudinal axis, the aerosol generating material has a second length along the longitudinal axis, and a ratio of the first length to the second length is between about <NUM> and about <NUM>. Another heater component has a mass of between about <NUM> and about <NUM>. A further heater component comprises an alloy comprising at least 99wt% Iron. A yet further heater component comprises carbon steel. A still further heater component defines a longitudinal axis and has a wall thickness, measured in a direction perpendicular to the longitudinal axis, of between about <NUM> and about <NUM>.

According to a first aspect of the present disclosure, there is provided an aerosol provision system comprising: an aerosol provision device comprising a chamber for receiving a consumable comprising aerosol-generating material, and an aerosol generator for generating aerosol from the aerosol-generating material when the consumable is located in the chamber, the chamber having a proximal end comprising an opening through which the consumable is insertable into the chamber, and a distal end comprising a tapered wall that tapers toward a central axis of the chamber with distance from the opening; and an adapter to selectively determine a maximum width of consumable insertable into the chamber via the opening.

The central axis of the chamber may extend in a direction orthogonal to a plane of the opening.

The aerosol provision device may comprise a consumable holder defining the chamber.

The adapter may be connectable, for example releasably connectable, to the aerosol provision device to selectively determine a maximum width of consumable insertable into the chamber via the opening.

The adapter may be positionable relative to the opening to partially block the opening. The adapter may be connectable, for example releasably connectable, to the aerosol provision device to partially block the opening.

The adapter may comprise a main body positionable relative to the opening to partially block the opening, and a bore through which the consumable is insertable into the opening, the bore formed in the main body, the bore having a width smaller than a maximum width of the opening. The bore may comprise a generally circular cross-section having a diameter smaller than a maximum width of the opening.

The bore may comprise a width in the region of <NUM>-<NUM>.

The chamber may comprise a main portion having a width greater than a width of the bore. The main portion may comprise a width substantially equal to a width of the opening. The main portion may extend between the proximal end and the distal end. The tapered wall and the adapter may be to support a consumable such that the consumable does not contact a wall defining the main portion. The wall defining the main portion may comprise a heater element for heating a consumable received in the chamber. The chamber may at least partially receive the consumable.

The adapter may comprise a first threaded connection and the aerosol provision device may comprise a second threaded connection, the first threaded connection releasably connectable to the second threaded connection to locate the adapter relative to the aerosol provision device. The aerosol provision device may comprise a consumable holder defining the chamber, and the consumable holder may comprise the first threaded connection. The aerosol provision device may comprise a housing within which the chamber is disposed, and the housing may comprise the first threaded connection.

The adapter may comprise a material having a melting point greater than <NUM>. The adapter may comprise polyether ether ketone (PEEK).

The adapter may comprise polyoxymethylene.

A wall of the chamber, for example a wall of the main portion, may comprise a material that is more heat resistant than a material of the adapter.

The aerosol provision system may comprise a plurality of adapters, each adapter to selectively determine a different maximum width of consumable insertable into the chamber via the opening. Each adapter may be to selectively determine a different maximum width of consumable insertable into the chamber via the opening when individually connected to the aerosol provision device. Each adapter may be to partially block the opening by a different degree. Each adapter may be to partially block the opening when individually connected to the aerosol provision device.

Each adapter may comprise a main body positionable relative to the opening to partially block the opening, and a bore through which the consumable is insertable into the opening, the bore formed in the main body, the bore of each adapter having a different width.

A first adapter of the plurality of adapters may comprise a bore with a width in the region of <NUM>-<NUM>, for example a diameter in the region of <NUM>-<NUM>.

A second adapter of the plurality of adapters may comprise a bore with a width in the region of <NUM>-<NUM>, for example a diameter in the region of <NUM>-<NUM>.

The aerosol provision system may comprise the consumable comprising aerosol-generating material.

The aerosol generator may comprise a heating assembly for applying heat to the consumable to generate aerosol from the aerosol-generating material when the consumable is located in the chamber. The heating assembly may comprise an induction heating assembly, for example a heating assembly comprising a magnetic field generator and a susceptor penetrable by a varying magnetic field to cause heating of the susceptor.

According to a second aspect of the present disclosure there is provided an aerosol provision device comprising a chamber for receiving a consumable comprising aerosol-generating material, an aerosol generator for generating aerosol from the aerosol-generating material when the consumable is located in the chamber, the chamber having a proximal end comprising an opening through which the consumable is insertable into the chamber, and a distal end comprising a tapered wall that tapers toward a central axis of the chamber with distance from the opening; and a connection mechanism for connecting to an adapter to selectively determine a maximum width of consumable insertable into the chamber via the opening.

An aerosol provision system, generally designated <NUM>, is shown schematically in <FIG>. The aerosol provision system <NUM> comprises an aerosol provision device <NUM> and an adapter <NUM>.

The aerosol provision device <NUM> comprises a housing <NUM>, a power source <NUM>, an aerosol generator in the form of a heating assembly <NUM>, a chamber <NUM>, a processor <NUM>, a computer readable memory <NUM>, and a user-operable control element <NUM>.

The housing <NUM> forms an outer cover of the aerosol provision device <NUM> and surrounds and houses the various components of the aerosol provision device <NUM>.

The power source <NUM> supplies electrical power to the various components of the aerosol provision device <NUM>, including, for example, the heating assembly <NUM>. In the embodiment of <FIG>, the power source <NUM> comprises a battery <NUM> and a DC-AC converter <NUM> to supply AC current to the heating assembly <NUM>. It will be appreciated that, in alternative embodiments, a heating assembly <NUM> may require DC current, and so the DC-AC converter <NUM> may be omitted or be replaced by a DC-DC converter, for example a buck or boost converter, as appropriate.

The aerosol provision device <NUM> may also comprise an electrical component, such as a socket/port (not shown), which can receive a cable to charge the battery <NUM>. For example, the socket may comprise a charging port, such as a USB charging port. In some examples the socket may be used additionally or alternatively to transfer data between the aerosol provision device <NUM> and another device, such as a computing device. The socket may also be electrically coupled to the battery <NUM> via electrical tracks.

The processor <NUM> is in data communication with the computer readable memory <NUM>. The processor <NUM> is configured to control various aspects of the operation of the aerosol provision device <NUM>. The processor <NUM> controls the various aspects by executing instructions stored on the computer readable memory <NUM>. For example, the processor <NUM> may control the operation of the heating assembly <NUM>. For example, the processor may control the delivery of electrical power from the power source <NUM> to the heating assembly <NUM> by controlling various electrical components such as switches and the like (not shown in <FIG>).

The user-operable control element <NUM> is, for example, a button or switch, which operates the aerosol provision device <NUM> when pressed. For example, a user may turn on the aerosol provision device <NUM> by operating the user-operable control element <NUM>, or may alter a setting of the heating assembly <NUM> by operating the user-operable control element <NUM>.

The heating assembly <NUM> of <FIG> is an induction heating assembly, and comprises a plurality of heating coils <NUM> and a susceptor <NUM>. The plurality of heating coils <NUM> are individually controllable, and are spaced along the chamber <NUM>, with the susceptor <NUM> embedded within the wall of the chamber <NUM>. It will be appreciated that other locations of susceptor <NUM> are also envisaged, and indeed that in some embodiments the susceptor <NUM> may be provided in a consumable that is received within the chamber <NUM> in use. It will further be appreciated that in some embodiments the susceptor <NUM> may comprise a plurality of susceptors, for example one susceptor per heating coil <NUM>.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, so that the susceptor is heatable by both heating mechanisms.

To cause heating of the chamber <NUM>, and therefore heating of a consumable received within the chamber <NUM>, the DC-AC converter <NUM> supplies the plurality of heating coils <NUM> with AC current, such that the plurality of heating coils <NUM> generate a varying magnetic field. The varying magnetic field interacts with the susceptor <NUM> to drive eddy currents within the susceptor <NUM>, with the flow of eddy currents causing heating of the susceptor <NUM>, and hence the chamber <NUM>. In such a manner a consumable received within the chamber <NUM> may be heated.

Whilst the heating assembly <NUM> described above utilises induction heating, it will be appreciated that other types of heating assembly may be used, for example other types of Joule heating assembly where current is driven along a resistive element.

It will further be appreciated that other forms of aerosol generator may be used that do not require heating. For example, in some embodiments, the aerosol generator is to cause an aerosol to be generated from the aerosol-generating material without heating. The aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

The chamber <NUM> is defined by a generally hollow tubular member <NUM>, as shown in cross-section in <FIG>. The tubular member <NUM> comprises an elongate hollow body, with an enlarged connection portion <NUM>. Internal walls of the tubular member <NUM> define the chamber <NUM>, with the chamber <NUM> having a proximal end <NUM> and a distal end <NUM>. The extent of the chamber <NUM> between the proximal end <NUM> and the distal end <NUM> may be referred to as a main portion <NUM> of the chamber <NUM>. The distal end <NUM> comprises a tapered wall <NUM>, which is tapered toward central axis A-A of the chamber <NUM>. An aperture <NUM> in the tapered wall <NUM> is in fluid communication with an air inlet <NUM> of the aerosol provision device <NUM>.

The proximal end <NUM> of the chamber <NUM> comprises an opening <NUM> through which a consumable (not shown in <FIG>) is insertable into the chamber <NUM>. The plane of the opening <NUM> extends between opposing sides of an internal wall <NUM> of the enlarged connection portion <NUM>, with the internal wall <NUM> comprising a threaded connection <NUM> for connecting to a threaded connection portion <NUM> of the adapter <NUM> as will be described hereafter.

In use the chamber <NUM> is configured to accommodate, one at a time, consumables comprising aerosol-generating material, with the heating assembly <NUM> being used to generate aerosol from the aerosol-generating material to be inhaled by a user. The chamber <NUM> may therefore be considered a heating chamber.

Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. In some embodiments, the aerosol-generating material may comprise an "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

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

As mentioned above, the aerosol provision device <NUM> receives aerosol-generating material to be heated in a consumable. A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. Such consumables are typically elongate and substantially cylindrical in form. However, consumables may be provided which have different dimensions, for example different lengths and/or diameters.

To enable the aerosol provision device <NUM> to be used effectively with consumables of different diameters, the aerosol provision system comprises the adapter <NUM>, which is shown in cross-section in <FIG>.

The adapter <NUM> comprises a threaded connection portion <NUM>, an abutment portion <NUM>, and a receiving portion <NUM>. Each of the threaded connection portion <NUM>, the abutment portion <NUM>, and the receiving portion <NUM> are generally cylindrical and hollow in form. Collectively the threaded connection portion <NUM>, the abutment portion <NUM>, and the receiving portion <NUM> define a main body of the adapter <NUM>. The threaded connection portion <NUM>, the abutment portion <NUM>, and the receiving portion <NUM> are integrally formed, for example such that the adapter <NUM> comprises a monolithic structure, and may be formed via a moulding process, for example a single-shot moulding process.

An outer surface of the threaded connection portion <NUM> is provided with a thread <NUM>, such that the threaded connection portion <NUM> defines a male connection for connection to the female connection of the enlarged connection portion <NUM>. An outer diameter of the threaded connection portion <NUM> is substantially equal to an inner diameter of the enlarged connection portion <NUM> of the tubular member <NUM>, such that the adapter <NUM> can be securely connected to the tubular member <NUM> via connection of the threaded connection <NUM> of the enlarged connection portion <NUM> with the threaded connection portion <NUM> of the adapter <NUM>. An inner diameter of the threaded connection portion <NUM> is substantially equal to a width of the opening <NUM>. An end face of the threaded connection portion <NUM> abuts a face of the enlarged connection portion <NUM> adjacent the opening <NUM> to prevent over-insertion of the adapter <NUM>.

The abutment portion <NUM> has an outer diameter substantially corresponding to an outer diameter of the enlarged connection portion <NUM>, such that the abutment portion <NUM> is able to contact an end face of the enlarged connection portion <NUM> to prevent over insertion of the adapter <NUM> into the enlarged connection portion <NUM>.

A bore <NUM> is formed through the abutment portion <NUM> and the receiving portion <NUM>, with a width, for example a diameter, of the bore <NUM> being less than a width of the opening <NUM>. The exact dimensions of the bore <NUM> will depend on a consumable that the adapter <NUM> is intended to be used with, but a typical diameter of the bore may be in the region of <NUM>-<NUM>, or in the region of <NUM>-<NUM>. The bore <NUM> is provided with a tapered entry, which may facilitate insertion of a consumable through the bore <NUM>.

An in-use configuration where the adapter <NUM> is connected to the tubular member <NUM> is shown schematically in <FIG>. The adapter <NUM> is connected to the enlarged connection portion <NUM> of the tubular member <NUM> by engagement of the threaded connection <NUM> of the enlarged connection portion <NUM> with the threaded connection portion <NUM> of the adapter <NUM>, with the abutment portion <NUM> engaged with end faces of the enlarged connection portion <NUM>. In some examples the engagement is such that the adapter <NUM> is located external of the housing <NUM>, whereas in other examples the engagement may be such that the adapter <NUM> is located internally within the housing <NUM>.

In the latter example, the housing <NUM> may comprise a removable end wall to allow for insertion and removal of the adapter <NUM>.

A consumable <NUM> is inserted through the bore <NUM>, through the opening <NUM> and into the chamber <NUM>. A first end <NUM> of the consumable <NUM> is in contact with the tapered wall <NUM>, whilst a portion of the main body of the consumable spaced from the first end <NUM> is held within the bore <NUM>. Thus the consumable <NUM> may be securely held via the bore <NUM> and the tapered wall <NUM>. The tapered wall <NUM> and the adapter <NUM> may enable the aerosol provision device <NUM> to be used with consumables of different widths, for example different diameters, whilst securely holding the consumables.

As the bore <NUM> has a width, for example a diameter, less than a width of the opening <NUM>, the adapter <NUM>, and in particular the main body of the adapter <NUM>, partially blocks the opening <NUM>, and the consumable <NUM> is supported such that there is a gap between the wall of the chamber <NUM> and the consumable <NUM>. This may inhibit direct contact of the consumable <NUM> with the wall of the chamber <NUM>, which may facilitate insertion and removal of the consumable <NUM> from the chamber <NUM>.

From <FIG>, it can be seen that the adapter <NUM> is located such that it is remote from the main portion <NUM> of the chamber <NUM>, which is the region in which the susceptor <NUM> is located, and hence remote from an area at which the chamber <NUM> is heated. This may allow the adapter <NUM> to be formed of a material that is less heat resistant than a wall of the chamber <NUM>, for example than the tubular member <NUM>. In any event, and to minimise the risk of deformation of the adapter <NUM> in use, in some examples the adapter <NUM> is formed from a material having a melting point of greater than <NUM>. This may ensure that the adapter <NUM> can withstand normal operating temperatures of the aerosol provision device <NUM> in use.

In some examples the adapter <NUM> may be formed of polyether ether ketone (PEEK). PEEK, however, may be a relatively expensive material, and so in other examples the adapter may be formed of polyoxymethylene (acetal). Forming the adapter <NUM> of polyoxymethylene (acetal) may also provide for easier formation of the threaded connection portion <NUM> than for a corresponding adapter made from PEEK.

As previously mentioned, consumables may be provided which have different dimensions, for example different lengths and/or diameters. To enable the aerosol provision device <NUM> to be used with further consumables with different diameters, a second adapter <NUM> may be provided as part of the aerosol provision system <NUM>.

The second adapter <NUM> is shown in isolation with the first adapter <NUM> in <FIG>. The second adapter <NUM> has substantially the same form as the first adapter <NUM>, and differs only in the width, i.e. the diameter, of the bore <NUM>. As shown in <FIG> the first adapter <NUM> has a bore <NUM> having a diameter in the region of <NUM>-<NUM>, whilst the second adapter <NUM> has a bore <NUM> having a diameter in the region of <NUM>-<NUM>. Thus the first <NUM> and second <NUM> adapters may partially block the opening <NUM> to a different degree, and allow the insertion into the opening <NUM> of consumables having different diameters. The tapered wall <NUM> may further allow the aerosol provision device <NUM> to accommodate consumables of different diameters.

It will be appreciated by a person skilled in the art that any number of adapters may be provided, with each adapter having a bore dimensioned to hold a consumable of a different diameter therein. It will also be appreciated that the aerosol provision device may be used with a plurality of different consumables, only some of which require the use of the adapter.

Claim 1:
An aerosol provision system (<NUM>) comprising:
an aerosol provision device (<NUM>) comprising a chamber (<NUM>) for receiving a consumable (<NUM>) comprising aerosol-generating material, and an aerosol generator (<NUM>) for generating aerosol from the aerosol-generating material when the consumable (<NUM>) is located in the chamber (<NUM>), characterised in that the chamber (<NUM>) has a proximal end (<NUM>) comprising an opening (<NUM>) through which the consumable (<NUM>) is insertable into the chamber (<NUM>), and a distal end (<NUM>) comprising a tapered wall (<NUM>) that tapers toward a central axis of the chamber with distance from the opening (<NUM>); and
the aerosol provision device (<NUM>) comprises an adapter (<NUM>) to selectively determine a maximum width of consumable (<NUM>) insertable into the chamber (<NUM>) via the opening (<NUM>).