Patent ID: 12207684

FIGS.1and2show an aerosol-generating device102of an aerosol-generating system according to an embodiment of the present invention. The device102is generally elongate and cylindrical and comprises a main body portion103at a first end and a heating portion104at a second end, opposite the first end. The main body portion103includes an outer housing105, which houses a power supply, control apparatus and charging port (not shown). The heating portion104includes a generally cylindrical heating chamber106, which is generally defined by a cylindrical side wall108projecting from one end of the main body portion103, coaxial to the main body. The heating chamber106comprises an opening110at a first end112, distal to the main body103, and is closed at a second end114, opposite the first end112, by a base116positioned at the main body portion103. The heating portion104further includes an extractor120removably positionable over the cylindrical side wall108.FIG.1shows a perspective view of the aerosol-generating device102partly disassembled with the extractor120removed.FIG.2shows a cut-through view of the aerosol-generating device102fully assembled with the extractor120received over the heating chamber106.

As shown inFIG.1, the cylindrical side wall108defines a plurality of vents109extending through the side wall108. The vents109are configured to enable air to enter the heating chamber106from the outside. Each vent109is generally elongate and extends substantially parallel to the central axis of the heating chamber106. The vents109are spaced evenly around the circumference of the side wall108at a substantially centrally between the first end112and the second end116.

The cylindrical side wall108further defines a side opening118at the second end of the heating chamber106, which will be described in more detail later on.

As shown inFIG.2, a heater130extends into the heating chamber106through the base116at the closed second end114. The heater130comprises a resistive heating element (not shown) that is connected to the power supply and control unit in the main body portion103of the device102. The heater130is configured as an internal heater for penetrating into an aerosol-forming substrate received in the heating chamber106. The heater130is in the form of an elongate, planar, heating blade terminating at a tapered end or a point at the end distal to the base116. The heater130extends into the heating chamber106in a direction substantially parallel with the cylindrical side wall108. The heater130is arranged centrally within the heating chamber106, such that the heater130is substantially aligned with the central longitudinal axis of the heating chamber106. The heater130is elongate, which means that the heater130has a length dimension that is greater than its width dimension and its thickness dimension. The heater130is also thin, which means its thickness dimension is substantially less than its length dimension and its width dimension. First and second opposing faces of the heater130are defined by the length and the width of the heater130. In this embodiment, the length of the heater130is about half the length of the cylindrical side wall108. In other words, the heater130extends about half way into the heating chamber106. Since the heater130extends only partially the length of the heating chamber106, the cylindrical side wall108provides some protection to the heater130by preventing access to the heater130from the side. It will be appreciated that in other embodiments, the heater130may extend into the heating chamber106by different amounts, for example, the heater130may extend about three quarter of the way into the heating chamber or may extend substantially the entire length of the heating chamber.

As shown inFIGS.1and2, the extractor120is removably receivable over the cylindrical side wall108. The extractor120comprises an outer sleeve122and a sliding receptacle124received in the outer sleeve122.

The outer sleeve122is generally in the form of a cylindrical tube that is open at both ends. The outer sleeve122has an external diameter that is substantially the same as the diameter of the housing105of the main body portion103, such that the outer sleeve122and the housing105of the main body portion103form a substantially continuous cylindrical shape when the extractor120is received on the cylindrical side wall108.

The sliding receptacle124is generally in the form of a cylindrical tube that is open at a first end and substantially closed at a second end, opposite the first end. The sliding receptacle124defines a chamber for receiving aerosol-forming substrate. The second end of the sliding receptacle124is substantially closed except for a central opening125that is configured to receive the heater130when the extractor120is received on the side wall108. The central opening125of the second end of the sliding receptacle124is slightly larger than the heater130such that an air gap is provided between the second end of the sliding receptacle and the heater130when the extractor120is received over the cylindrical side wall108. A flange126protrudes outwards from the sliding receptacle124at the open end. The sliding receptacle124is received in the outer sleeve122and secured to the outer sleeve122at the flange126at the first end.

The sliding receptacle124has an outer diameter that is smaller than the inner diameter of the outer sleeve122, such that an annular gap127is provided between the outer sleeve122and the sliding receptacle124. The annular gap127is sized and configured to receive the cylindrical outer wall108. The outer diameter of the sliding receptacle124is slightly smaller than the inner diameter of the cylindrical side wall108, such that the sliding receptacle124may be easily received in the heating chamber106. The inner diameter of the outer sleeve122is slightly larger than the outer diameter of the cylindrical side wall108, such that an air gap is formed between the outer sleeve122and the cylindrical side wall108when the extractor120is received over the cylindrical side wall108. The flange126provides a stop against which the outer end of the cylindrical side wall108abuts when the extractor120is fully received over the cylindrical side wall108.

InFIG.2, the extractor120is shown in a first position, or an operating position, where the extractor is fully received over the cylindrical side wall108. In this position, the cylindrical side wall108is fully received in the annular gap127, with the end of the side wall108abutting the flange126of the extractor120.

The first open end of the outer sleeve122and the open end of the sliding receptacle124are arranged substantially flush with each other. However, the length of the outer sleeve122is greater than the length of the sliding receptacle124. As shown inFIG.2, the outer sleeve122has a length sufficient to abut the housing105of the main body portion103when the extractor120is in the operating position. The sliding receptacle124has a length sufficient to provide a space between the base114of the heating chamber106and the substantially closed second end of the sliding receptacle124when the extractor120is in the operating position. A base portion132of the heater130extends through the space. The heating element (not shown) of the heater130does not extend over the base portion132of the heater130. The side opening118in the cylindrical side wall108is aligned with the space between the base114and the second end of the sliding receptacle124.

Typically, an aerosol-generating article (not shown) that is suitable for use with the device102ofFIGS.1and2is generally in the form of a conventional cigarette. The article comprises an aerosol-forming substrate, such as a rod of tobacco, at a distal end, and a filter at a proximal end, opposite the distal end. The article may have a width or diameter that is slightly smaller than the inner diameter of the sliding receptacle124of the extractor120, such that the article may be easily inserted into the chamber of the sliding receptacle124and removed from the chamber of the sliding receptacle124. The aerosol-forming substrate may have a length that is substantially similar to or slightly larger than the length of the portion of the heater130between the base portion132and the tapered end (i.e. the portion of the heater130that extends into the chamber of the sliding receptacle124when the extractor120is in the first position). This sizing enables the heater130to extend through substantially the entire length of the aerosol-forming substrate when the aerosol-generating article is receive in the heating chamber106of the device102.

In use, when the extractor120received over the heating chamber106in the first (operating) position, the aerosol-generating article (not shown) may be inserted into the heating chamber106of the device102through the open end of the sliding receptacle124of the extractor120. As the article is inserted into the heating chamber106, the tapered end of the heater130encounters the aerosol-forming substrate at the distal end of the article and pierces the substrate. The aerosol-generating article may be moved further into the heating chamber106until the distal end of the article abuts the substantially closed second end of the sliding receptacle124. In this fully received position, the heater130extends into the aerosol-forming substrate along substantially the entire length of the aerosol-forming substrate.

When the device102is turned on, power is supplied to the heater130from the power supply (not shown) in the main body portion103. The heater130heats the aerosol-forming substrate at the distal end of the aerosol-generating article and volatile substances are generated or evolved from the aerosol-forming substrate. When a user draws on the mouth end of the aerosol-generating article, air is drawn into the device102and through the aerosol-generating article, from the distal end to the mouth end, for inhalation by the user. Air is drawn into the device102through air inlets (not shown) in the outer wall122of the extractor120and is drawn into the heating chamber106, into the space between the cylindrical side wall108and the outer surface of the sliding receptacle124, through the vents109in the cylindrical side wall108. Air between the cylindrical side wall108and the outer surface of the sliding receptacle124is drawn into the chamber of the sliding receptacle124through the air gap between the heater130and the closed second end of the sliding receptacle124. The air entering the chamber of the sliding receptacle124is drawn into the aerosol-generating article through the distal end, such that the air encounters the aerosol-forming substrate that is being heated by the heater130. The volatile substances evolved from the heated aerosol-forming substrate are entrained in the air entering the aerosol-generating article at the distal end, and are drawn with the air from the distal end of the article to the mouth end. As the volatile substances are drawn through the article, they condense to form an inhalable aerosol. The aerosol is drawn out of the article at the mouth end for inhalation by the user.

During insertion of the aerosol-generating article into the heating chamber120and during removal of the aerosol-generating article120from the heating chamber120, loose debris may be released from the aerosol-forming substrate into the heating chamber120. In particular, loose debris may be created around the heater130as the substrate is moved against the heater130. The loose debris may accumulate at the closed second end114of the heating chamber106. In particular, debris may accumulate in corners of the heating chamber106where the base116meets the heater130.

As shown inFIGS.1and2, a residue collector1, according to an embodiment of the present invention, is removably disposed in the heating chamber106of the device102. The residue collector1is positioned at the second end114of the heating chamber106, supported on the base116. Specifically, the residue collector1is positioned in the space between the base114and the substantially closed second end of the sliding receptacle124. The residue collector1substantially surrounds or circumscribes the base portion132of the heater130. In other words, the residue collector1substantially covers a portion of the base116around the heater130. In this position, the residue collector is positioned at the position of the base116at which the majority of the loose debris released from aerosol-forming substrate accumulates. Accordingly, the residue collector1of the present invention is positioned to intercept debris before it reaches the base116of the heating chamber106. Thus, the residue collector1may facilitate removal of the debris from the heating chamber106.

The residue collector1has a rounded rectangular profile, having substantially planar sides and a front and rear end that are curved. The front and rear ends are curved with substantially the same curvature as the cylindrical side wall108. The length of the planar sides is complimentary of the size of the base114of the heating chamber106, such that the curved front and rear ends of the residue collector are flush with the cylindrical side wall108when the residue collector1is fully received in the heating chamber106. The residue collector has a height or thickness between the first and second faces that is slightly smaller than the height of the space between the base114and the second end of the residue collector124, such that the residue collector1extends substantially between the base114and the second end of the sliding receptacle124when the extractor120is received over the cylindrical side wall108.

In this embodiment, the residue collector1is positioned in a space between the base116of the heating chamber106and the sliding receptacle124of the extractor120. However, it will be appreciated that in other embodiments, the residue collector1may be positioned in the chamber of the sliding receptacle124, between the substantially closed second end of the sliding receptacle124and an aerosol-forming substrate received in the chamber. In these embodiments, the sliding receptacle may extend to the base114of the heating chamber106. In these embodiments, the outer sleeve122and the sliding receptacle may require side openings to facilitate insertion and removal of the residue collector. However, the cylindrical side wall108of the heating chamber106may not require a side opening118. An advantage of adapting the extractor120to accept the residue collector may be that debris that would otherwise accumulate in the extractor may be easily removed with the residue collector1.

The side opening118in the cylindrical side wall108of the device102is provided to facilitate insertion of the residue collector1into the heating chamber106and removal of the residue collector1from the heating chamber106. Accordingly, the side opening118has a similar height and width to the residue collector1, to enable the residue collector to be inserted into the heating chamber106through the side opening118and removed from the heating chamber108through the side opening118. The side opening118is elongate and extends transverse to the central axis of the heating chamber106. The side opening108has a width substantially equal to the width of the residue collector1and a height substantially equal to the height of the residue collector1. The side opening108is positioned between the vents109and the closed second end of the heating chamber106, at the space between the base114and the second end of the sliding receptacle124when the extractor120is received on the cylindrical side wall108.

In this embodiment, the residue collector1does not have a substantially circular profile, and as such, the residue collector does not cover the entire base114when the residue collector1is fully received in the heating chamber106. Peripheral portions of the base114at either side of the side opening118are not covered by the residue collector. These uncovered peripheral portions of the base are unlikely to accumulate residue from aerosol-forming substrate in the heating chamber106, as these portions of the base are directly below closed portions of the sliding receptacle124. In some embodiments, the residue collector may have a profile substantially similar to that of the heating chamber and the residue collector may substantially cover the entire base. However, in these embodiments, the side opening of the side wall of the heating chamber may be required to extend the entire width of the heating chamber in order to enable insertion and removal of the residue collectors. It may not be necessary to increase the size of the side opening in embodiments where the residue collector is compressible to reduce the width of the residue collector on insertion and removal.

FIGS.3a-dshow specific embodiments of residue collectors in accordance with the present invention.

FIG.3ashows a first embodiment of the residue collector1. The residue collector1comprises a body defined between a first face16and a second face18. A side wall14extends between the first face16and the second face18, defining the periphery of the residue collector1. The residue collector1has a substantially rounded rectangular transverse cross section, such that the residue collector1generally has an elongate shape with planar sides and a rounded ends. In this embodiment, one of the rounded ends may be considered to be a front end10and the opposite rounded end may be considered to be a rear end11.

In the embodiment ofFIG.3a, the residue collector1defines a slot13extending between the first face16and the second face18, such that the slot is open at the first face16and the second face18. The slot13is an elongate opening through the body of the residue collector1. The slot13extends from the side wall14at the front end10of the residue collector1towards a central portion of the residue collector1. In other words, the slot13is open at the front end10. Additionally, the residue collector1includes a lip9projecting around the edge of the first face16. The lip9projects upwards, away from the first face16, and defines a recessed portion or open cavity8around the slot13. In this embodiment, the lip9is wide, extending across a large proportion of the first face16. Accordingly, the open cavity8is a narrow recessed portion. When the residue collector is fully received in the heating chamber, the open cavity8is arranged directly below the opening in the second end of the sliding receptacle124. The open cavity8has a similar size to the opening in the second end of the sliding receptacle, so that the majority of debris falling through the opening may be received in the open cavity8.

To prepare the device102for use, before the extractor120is received over the cylindrical side wall108, the residue collector1is inserted into the heating chamber106of the device102through the side opening118in the cylindrical side wall108, as shown inFIG.4. The front10of the residue collector1is inserted into the side opening118, and the slot13receives the base portion132of the heater130. When the residue collector1is fully inserted into the heating chamber106, the heater130abuts the end of the slot13, the front10abuts the cylindrical side wall108, the rear11is positioned flush with the cylindrical side wall108and the second face18is supported on the base114of the heating chamber106, as shown inFIG.2. Since the rear11of the residue collector1is flush with the cylindrical side wall108, the outer sleeve122of the side wall may slide over the side opening118, past the residue collector1, without contacting the residue collector1. During use of the device102, debris that falls from an aerosol-generating article inserted into the heating chamber106collects on the first face16of the residue collector1. Debris that accumulates in the recessed portion8may be retained by the lip9, particularly during removal of the residue collector1from the device102. Removal of the residue collector1from the heating chamber106may be performed after the extractor120and the article have been removed from the heating chamber106.

A second embodiment of a residue collector1according to the present invention is shown inFIG.3b. In the second embodiment, the residue collector1has substantially the same shape as the first embodiment of the residue collector1shown inFIG.3a; however the residue collector1of shown inFIG.3bdefines two additional elongate slits17. The elongate slits17extend between the first face16and the second face18of the residue collector1, similar to the slot13. The elongate slits17are positioned both sides of the slot13, and extend substantially parallel to the slot13. The elongate slits17extend from the front10of the residue collector1. The elongate slits17are not configured to receive a heater of the aerosol-generating device, but rather are configured to enable the width of the residue collector1to be compressed to facilitate insertion and removal.

During insertion of the residue collector1into the heating chamber106, an inward force can be applied to the side walls14on both sides of the residue collector1, between the front10and rear11of the residue collector1. When such an inward force is applied, the sides of each elongate slit17may be brought together such that the width of the residue collector is reduced. Reducing the width of the residue collector1may allow the residue collector1to be more easily inserted into the side opening118of the device102.

A third embodiment of the residue collector1according to the present invention is shown inFIG.3c. The residue collector1shown inFIG.3cis substantially similar to the second embodiment of the residue collector1shown inFIG.3b, however, the residue collector1shown inFIG.3ccomprises four elongate slits17, two slits at either side of the slot13. The two additional elongate slits17may allow the width of the residue collector1to be compressed even further.

A fourth embodiment of the residue collector1according to the present invention is shown inFIG.3d. The residue collector1shown inFIG.3dis has a substantially similar transverse cross-sectional shape to first embodiment of the residue collector1shown inFIG.3a. However the residue collector1shown inFIG.3dhas several different features to the first embodiment of the residue collector1.

The lip9of the residue collector1shown inFIG.3dis narrow and extends around the periphery of the residue collector1. The lip9extends upwards from the first face16of the residue collector1and with the first face16of the residue collector1defines an open cavity19. A plurality of projections17also extend upwards from the first face16within the open cavity19. The upward projections17are regularly spaced across the open cavity19in a regular pattern, such that the spaces between the projections17in the cavity19form orifices in a honeycomb pattern. The upward projections17and the lip9extend substantially the same distance from the first face16, and as such the ends of the lip9and the projections17generally lie on a plane.

In use, debris that accumulates on the residue collector1may fall into the cavity19, between the upward projections17, onto the first face16. During removal of the residue collector1, the debris collected by the residue collector1may be trapped in the cavity19, which may substantially prevent debris from being dislodged from the residue collector1and falling into the heating chamber106during removal of the residue collector1from the heating chamber106.

The slot13of the residue collector1ofFIG.3dalso comprises cut-outs15on both sides of the slot13. The cut outs15extend from the slot13towards the side walls14of the residue collector1. The cut-outs15extend between the first face16and the second face18, similarly to the slot13. However, it will be appreciated that in some embodiments the cut-outs15may only extend partially from the first face16towards the second face18. The areas between the cut-outs15define a comb like structure, with each area comprising a projecting elements15′ extending from the body of the residue collector inwards towards the central axis of the slot13.

When the residue collector1shown inFIG.3dis inserted into the heating chamber106of the device102, the ends of the projecting elements15′ abut the base portion132of the heater130. As such, during removal of the reside collector1from the heating chamber106, the ends of the projecting elements15′ are drawn against the base portion132of the heater130. This allows the projecting elements15′ to wipe clean residue from the base portion132of heater130during removal. The projecting elements15′ may deform when the residue collector1is inserted into the heating chamber106. As such, the projecting elements15′ are generally configured to be resiliently deformable, such that they are not damaged during insertion and removal.

In all of the above embodiments, the residue collector1has a substantial thickness. However, it will be appreciated that in some embodiments, the residue collector may be a thin plate or sheet. Where the residue collector is a thin plate or sheet, the rigidity of the residue collector may be required to be increased, so that the residue collector does not deform or break during insertion and removal.

Another embodiment of the aerosol-generating device102is shown inFIGS.5a-c. The device102shown inFIGS.5a-cis substantially identical to the device102shown inFIGS.1and2; and like references numerals are used to indicate like features. However, the device102shown inFIGS.5a-ccomprises two opposing side openings118a,118bin the cylindrical side wall108. For the sake of clarity, the extractor120is not shown inFIGS.5a-c. The two opposing side openings118a,118benable a residue collector1to be inserted and removed from either side of the device102. In particular, a first residue collector1positioned within the heating chamber106, which was inserted through the first side opening118a, may be removed from the heating chamber106through the first side opening118aby being pushed back out of the first side opening118aby a second residue collector1′ being inserted through the second side opening118b. Such a replacement process is shown inFIGS.5a-c.

In more detail, to remove a first residue collector1from the heating chamber106of the device102ofFIGS.5a-c, the front10′ of the new second residue collector1′ may be positioned to abut the front10of the used residue collector1at the second opening118b, as shown inFIG.5a. As the second residue collector1′ is moved through the second side opening118b, into the heating chamber106, the first residue collector1may be pushed out of the heating chamber106through the first side opening118a, as shown inFIGS.5band5c. Accordingly, insertion and removal can be combined into a single act.

In both of the above embodiments, the aerosol-generating device comprises an extractor. However, it will be appreciated that in some embodiments of the invention, the aerosol-generating device may not comprise such an extractor. In these embodiments, the residue collector may be positionable at or towards the second end of the heating chamber and sized such that the residue collector does not interfere with the aerosol-generating process.