Patent ID: 12201157

DETAILED DESCRIPTION

It should be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

It should be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of example embodiments.

Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper,” and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing various embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of example embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, example embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

FIG.1shows a cross-sectional view of an aerosol-generating device10according to an example embodiment. The aerosol-generating device10comprises a housing12defining a cavity14for receiving an aerosol-generating article. An air inlet16is provided at an upstream end of the cavity14and a mouthpiece18is provided at a downstream end of the housing12. An air outlet20is provided in the mouthpiece18in fluidic communication with the cavity14so that an airflow path is defined through the cavity14between the air inlet16and the air outlet20. During vaping, a negative pressure is applied to the mouthpiece18to draw air into the cavity14through the air inlet16and out of the cavity14through the air outlet20.

The aerosol-generating device10further comprises a plurality of electrical heaters22provided on a planar wall24of the cavity14. Each of the electrical heaters22comprises a heater element26provided on a common support layer28. The plurality of electrical heaters22form a heater array30, which is shown more clearly inFIG.2.

The aerosol-generating device10also comprises a segmented visual feedback device32, which is shown more clearly inFIG.3. In an example embodiment, the segmented visual feedback device32comprises a plurality of segments34arranged in an array having the same pattern as the heater array30. In the example embodiments shown inFIGS.1to3, each segment34comprises a blue LED, a red LED, and a green LED so that each segment34can be illuminated in a variety of different colours.

The aerosol-generating device10further comprises an electrical power supply40and a controller42positioned within the housing12. When an aerosol-generating article is received within the cavity14, the controller42controls a supply of electrical current from the electrical power supply40to each electrical heater22to activate the electrical heater22. In an example embodiment, the controller42is configured to activate the plurality of electrical heaters22in groups, with each group being activated and deactivated sequentially. The controller42is also configured to switch each of the segments34of the segmented visual feedback device32from a first condition36to a second condition38when the corresponding electrical heater22in the heater array30is activated. In the first condition36, each segment34may be switched off, and in the second condition38each segment34may be switched on and illuminated in a first colour. When all of the electrical heaters22have been activated, the controller42is configured to switch all of the segments34of the segmented visual feedback device32to a third condition. In the third condition, all of the segments34may be switched on and illuminated in a second colour that is different from the first colour. When the aerosol-generating article is removed from the cavity14and a new aerosol-generating article is inserted into the cavity14, the controller42resets all of the segments34to the first condition.

FIG.4shows an aerosol-generating article50for use with the aerosol-generating device10ofFIGS.1to3. The aerosol-generating article50comprises a base layer52and an aerosol-forming substrate54provided on the base layer52. In an example embodiment, the aerosol-forming substrate54comprises a substantially continuous layer of a solid tobacco-containing material. A removable cover layer56is secured to the base layer52to seal the aerosol-forming substrate54between the base layer52and the removable cover layer56. The removable cover layer56may be formed from a non-porous polymeric film.

During use, the removable cover layer56is removed from the base layer52and the aerosol-generating article50is inserted into the cavity14of the aerosol-generating device10shown inFIG.1to form an aerosol-generating system. The controller42then sequentially activates and deactivates groups of the electrical heaters22to sequentially heat discrete portions of the aerosol-forming substrate54. Each time an electrical heater22is activated, the controller42switches the corresponding segment34of the segmented visual feedback device32into the second condition to indicate that the corresponding portion of the aerosol-forming substrate54has been depleted. In this way, the segmented visual feedback device32provides a clear indication of the level of depletion of the aerosol-forming substrate54.

FIG.5shows another aerosol-generating article60for use with the aerosol-generating device10ofFIGS.1to3. The aerosol-generating article60comprises a base layer52and a cover layer56identical to the base layer52and the cover layer56of the aerosol-generating article50shown inFIG.4. However, the aerosol-generating article60comprises a plurality of discrete aerosol-forming substrates64positioned on the base layer52and sealed between the base layer52and the cover layer56. Each of the aerosol-forming substrates64may comprise a porous substrate material and a liquid aerosol-forming substrate sorbed onto the porous substrate material.

In an example embodiment, the plurality of aerosol-forming substrates64is divided into three groups: a plurality of first aerosol-forming substrates68each comprising a liquid nicotine solution; a plurality of second aerosol-forming substrates70each comprising a volatile acid; and a plurality of third aerosol-forming substrates72each comprising a flavourant.

During use, the removable cover layer56is removed from the base layer52and the aerosol-generating article60is inserted into the cavity14of the aerosol-generating device10shown inFIG.1to form an aerosol-generating system80, as shown inFIG.6. In an example embodiment, the arrangement of the aerosol-forming substrates64is such that each aerosol-forming substrate64overlies an electrical heater22when the aerosol-generating article60is received within the cavity14.

The controller42then sequentially activates and deactivates groups of the electrical heaters22to sequentially heat the discrete aerosol-forming substrates64. At each stage of the sequential activation, the controller42activates the appropriate electrical heaters22to simultaneously heat one of the first aerosol-forming substrates68, one of the second aerosol-forming substrates70, and one of the third aerosol-forming substrates72. The nicotine vapour released from the heated first aerosol-forming substrate68and the acid vapour released from the heated second aerosol-forming substrate70react in the gas phase to form an aerosol comprising nicotine salt particles for delivery through the air outlet20. The flavourant released from the heated third aerosol-forming substrate72imparts a flavour to the aerosol.

Each time an electrical heater22is activated, the controller42switches the corresponding segment34of the segmented visual feedback device32into the second condition to indicate that the corresponding discrete aerosol-forming substrate64has been depleted. In this way, the segmented visual feedback device32provides a clear indication of the level of depletion of the plurality of discrete aerosol-forming substrates64.

FIG.7shows an exploded view of an aerosol-generating article90according to an example embodiment. The aerosol-generating article90comprises a base layer52and a plurality of discrete aerosol-forming substrates64that are identical to the base layer52and aerosol-forming substrates64of the aerosol-generating article60shown inFIG.5. Therefore, like reference numerals are used to designate like parts.

The aerosol-generating article90comprises a cover layer92attached to the base layer52and overlying the plurality of discrete aerosol-forming substrates64. A segmented visual feedback device94is positioned on the cover layer92, the segmented visual feedback device94comprising a plurality of segments96. In an example embodiment, the pattern formed by the plurality of segments96is identical to the pattern formed by the plurality of discrete aerosol-forming substrates64so that each segment96overlies a discrete aerosol-forming substrate64.

Each of the segments96of the segmented visual feedback device94may comprise a material that exhibits a change in the appearance of the material when heated. For example, each segment96may comprise at least one of a thermomechanical material, a thermochromic material, a material configured to exhibit a change in transparency when heated, and a material configured to exhibit a change in a polarizing effect of the material when heated.

FIG.8shows a cross-sectional view of an aerosol-generating device100for use with the aerosol-generating article90ofFIG.7. The aerosol-generating device100is substantially the same in construction and operation as the aerosol-generating device10ofFIGS.1to3, and like reference numerals designate like parts. The aerosol-generating device100comprises a transparent window102instead of a segmented visual feedback device32(like inFIG.1). The transparent window102is positioned so that it overlies the segmented visual feedback device94of the aerosol-generating article90when the aerosol-generating article90is received within the cavity14. When the aerosol-generating article90is received within the cavity14, the controller42sequentially activates the electrical heaters22to sequentially heat the plurality of discrete aerosol-forming substrates64, as described with reference toFIG.6. When each of the discrete aerosol-forming substrates64is heated, the heat causes the material of the corresponding segment96of the segmented visual feedback device94to exhibit a change in appearance. The change in appearance of each segment96can be observed through the transparent window102, and in this way the segmented visual feedback device94provides a clear indication of the level of depletion of the plurality of discrete aerosol-forming substrates64.

While a number of example embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.