HEATER FOR AN AEROSOL PROVISION DEVICE

Technical Field

The present invention relates to a heater for an aerosol provision device, an aerosol provision device, an aerosol provision system and a method of generating an aerosol.

Background

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 by creating products that release compounds without combusting. Examples of such products are so-called “heat not burn” products or tobacco heating devices or products, which release compounds by heating, but not burning, material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.

Aerosol provision systems, which cover the aforementioned devices or products, are known. Common systems use heaters to create an aerosol from a suitable medium which is then inhaled by a user. Often the medium used needs to be replaced or changed to provide a different aerosol for inhalation. It is known to use resistive heating systems as heaters to create an aerosol from a suitable medium. Separately, induction heating systems are known to be used as heaters.

Summary

According to an aspect there is provided a heater for an aerosol provision device comprising: an elongate housing defining a longitudinal axis; a first heater coil located within the housing; and a second heater coil located within the housing; wherein the first heater coil and the second heater coil are non-coincident in the direction of the longitudinal axis.

According to various embodiments a heater for an aerosol provision device may be provided comprising two heater coils. The heater coils may occupy different volumes with an inner cavity of an elongate housing. According to various embodiments an opening may be provided in the side of the elongate housing. The two heater coils may be inserted into the inner cavity and conductive pins may be arranged down the side. The two heater coils may be heated separately. According to various embodiments the two heater coils or heating coils may occupy different volumes within the inner cavity in order to facilitate electrical connections to each of the heater coils. In particular, embodiments are contemplated wherein two heater coils may be inserted to different insertion depths within the inner cavity. According to an embodiment, two or more heater coils may be displaced longitudinally from each so that either there is no overlap in the longitudinal direction or alternatively there is only a small partial overlap in the longitudinal direction. For example, embodiments are contemplated wherein a first heater coil has a longitudinal length L1 and a second heater coil has a longitudinal length L2. The two heater coils may be space longitudinally by a distance of at least 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm or > 10 mm. According to an embodiment the two coils may overlap longitudinally by a distance which is < 5% or < 10% of the length L1 or L2.

Embodiments are contemplated wherein the two heater coils may be co-axial. Other embodiments are contemplated wherein the two heater coils have longitudinal axes which are parallel and non-overlapping to each other.

According to an embodiment there is provided a heater for an aerosol provision device comprising an elongate housing defining a longitudinal axis extending in a longitudinal direction, a first heater coil located within the housing, the first heater coil having a first position in the longitudinal direction and a second heater coil located within the housing, the second heater coil having a second position in the longitudinal direction that is different to the first position.

The elongate housing may comprise an inner cavity. The elongate housing may be configured to provide access to the inner cavity through a longitudinally extending surface of the housing during at least part of the manufacturing process of the heater.

According to various embodiments the first heater coil and the second heater coil do not overlap longitudinally.

According to an alternative embodiment, the first heater coil and the second heater coil may at least partially overlap in the longitudinal direction. However, embodiments are contemplated wherein the degree of overlap is < 5% of the longitudinal length of one, or both, of the heater coils.

The first heater coil and the second heater coil may have the same configuration as each other.

According to another aspect there is provided an aerosol provision device configured to heat an article comprising aerosol generating material, the device comprising a heater as described above. The aerosol provision device may further comprise one or more controllers for controlling operation of the first heater coil and the second heater coil.

The one or more controllers may be arranged to control the first heater coil independently of the second heater coil.

The one or more controllers may be arranged to control the first heater coil to have a first heating profile and the second heater coil to have a second different heating profile.

The controller may be arranged to control the first heater coil and the second heater coil in parallel with each other.

According to another aspect there is provided a system comprising an aerosol provision device as described above and an article comprising aerosol generating material.

According to another aspect there is provided a method of manufacturing or assembling a heater for an aerosol provision device configured to heat an aerosol generating article containing aerosol generating material, wherein the method comprises: providing an elongate housing defining a longitudinal axis; locating a first heater coil within the housing; and locating a second heater coil located within the housing; wherein the first heater coil and the second heater coil are non-coincident in the direction of the longitudinal axis.

According to an embodiment there is provided a method of manufacturing or assembling a heater for an aerosol provision device configured to heat an aerosol generating article containing aerosol generating material, wherein the method comprises: providing an elongate housing defining a longitudinal axis extending in a longitudinal direction; locating or inserting a first heater coil within the housing at a first position in the longitudinal direction; and locating or inserting a second heater coil within the housing at a second position in the longitudinal direction that is different to the first position.

The method may comprise accessing an inner void through a longitudinally extending surface of the housing to locate at least one of the first heater coil and the second heater coil within the housing. According to another aspect there is provided a method of generating an aerosol comprising: providing an aerosol provision device as described above; and at least partially inserting an aerosol generating article comprising aerosol generating material within the aerosol provision device.

The method may further comprise activating the aerosol provision device.

The heater may be a resistive heating heater. The heating member may be a resistive heating member. The heating element may be a resistive heating element. The coil may be a resistive heating heater coil

The heater may be an inductive heating heater. The heating element may be an inductive heating element. The coil may be an inductive coil.

According to an aspect, there is provided aerosol provision device configured to heat an article comprising aerosol generating material, the device comprising a heater described above. The aerosol provision device may comprise a heating chamber, in which the heater is provided.

The aerosol provision device may comprise a power source, a controller and a heating chamber, in which the aerosol generating article is removeable received. The power source may be aligned along a longitudinal axis of the heating chamber. The power source may be aligned along a second longitudinal axis, parallel to the longitudinal axis of the heating chamber.

The aerosol provision device may be configured for wireless charging.

According to an aspect there is provided an aerosol provision system comprising: an aerosol provision device as described above; and an article comprising aerosol generating material.

The aerosol provision system may comprise a charging unit having a cavity for removably receiving the aerosol provision device. The charging unit may comprise a moveable lid, which covers the aerosol provision device in a closed configuration. The charging unit may comprise a user display. The user display may be visible to a user when the moveable lid is in a closed position and is partially or fully concealed or obscured from sight by the lid when the lid is an open position.

According to another aspect there is provided a method of generating aerosol comprising: providing an aerosol provision device as described above and at least partially inserting an aerosol generating article into the receiving portion of the heating chamber.

Brief Description of the Drawings

Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings, in which:

Figure 1 shows a perspective view of an aerosol provision system including an aerosol provision device located within a charging unit;

Figure 2 shows a schematic cross-sectional view of part of the aerosol provision device of Figure 1;

Figure 3 shows a schematic cross-sectional view of part of the aerosol provision device of Figure 1 and an aerosol generating article of the aerosol provision system;

Figure 4 shows a perspective view of another aerosol provision device;

Figure 5 shows a schematic cross-sectional view of the device of Figure 4;

Figure 6 shows a schematic cross-sectional view of a heater of the device of Figure 1 or Figure 4;

Figure 7 shows a heater according to various embodiments wherein two heater coils are located within an inner cavity of an elongate housing and wherein the two heater coils are non-coincident in the direction of the longitudinal axis;

Figure 8(a) illustrates an embodiment wherein two heater coils are located so as to be non-coincident in the direction of the longitudinal axis, Figure 8(b) illustrates an embodiment wherein two heater coils are located so as to be non-coincident in the direction of the longitudinal axis, Figure 8(c) illustrates an embodiment wherein two heater coils are located so as to only partially overlap in the direction of the longitudinal axis and Figure 8(d) illustrates an arrangement wherein two heater coils have different lengths and a smaller heater coil is located within the volume of a larger heater coil; and

Figure 9 illustrates a method of manufacturing or assembling a heater according to various embodiments.

Detailed Description

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosolgenerating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device.

In some embodiments, the non-combustible aerosol provision device may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosolgenerating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

As used herein, the term “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 semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.

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.

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating material may comprise or be in the form of an aerosol-generating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosolgenerating material is substantially tobacco free.

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, it may be gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material.

The aerosol-generating film may be discontinuous. For example, the aerosolgenerating film may comprise one or more discrete portions or regions of aerosolgenerating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film. An aerosol provision device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into or onto the aerosol provision device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within or over a heater of the device which is sized to receive the article.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

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 aerosolmodifying 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.

A susceptor is a heating 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. The aerosol provision device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

Non-combustible aerosol provision systems may comprise a modular assembly including both a reusable aerosol provision device and a replaceable aerosol generating article. In some implementations, the non-combustible aerosol provision device may comprise a power source and a controller (or control circuitry). The power source may, for example, comprise an electric power source, such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol provision device may also comprise an aerosol generating component. However, in other implementations the aerosol generating article may comprise partially, or entirely, the aerosol generating component.

Figure 1 shows an aerosol provision system 10 comprising an aerosol provision device 100 and a charging unit 101. The device is shown located within a cavity of a charging unit 101. The aerosol provision device 100 is arranged to generate aerosol from an aerosol generating article (refer to Figure 3) which may be inserted, in use, into the aerosol provision device 100. In embodiments, the article forms part of the aerosol provision system 10.

The aerosol provision device 100 is an elongate structure, extending along a longitudinal axis. Additionally, the aerosol provision device has a proximal end, which will be closest to the user (e.g. the user’s mouth) when in use by the user to inhale the aerosol generated by the aerosol provision device 100, as well as a distal end which will be furthest from the user when in use. The proximal end may also be referred to as the “mouth end”. The aerosol provision device 100 also accordingly defines a proximal direction, which is directed towards the user when in use. Further, the aerosol provision device 100 also likewise defines a distal direction, which is directed away from the user when in use. The terms proximal and distal as applied to features of the device 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along a longitudinal axis. The aerosol provision device 100 comprises an opening at the distal end, leading into a heating chamber.

The aerosol provision device 100 may be removably inserted into the charging unit 101 in order to be charged. The charging unit 101 comprises a cavity for receiving the aerosol provision device 100. The aerosol provision device 100 may be inserted into the cavity via an opening. The cavity may also comprise a longitudinal opening. A portion of the aerosol provision device 100 may comprise a first side. One or more user- operable control elements such as buttons 106 which can be used to operate the aerosol provision device 100 may be provided on the first side of the aerosol provision device 100. The first side of the aerosol provision device 100 may be received in the longitudinal opening provided in the charging unit 101.

In embodiments the cavity of the charging unit 101 may have a cross-sectional profile which only permits that the aerosol provision device 100 be inserted into the charging unit 101 in a single orientation. According to an embodiment the outer profile of the aerosol provision device 100 may comprise an arcuate portion and a linear portion. The cross-sectional profile of the cavity provided in the charging unit 101 may also comprise a similar arcuate portion and a linear portion. The linear portion of the cross- sectional profile of the cavity may correspond with the longitudinal opening. The charging unit 101 includes a slidable lid 103. When the aerosol provision device 100 is inserted into the charging unit 101 in order to be recharged, the slidable lid 103 may be closed so as to cover the opening into the aerosol provision device 100. In other embodiments, the charging unit 101 may have an alternative lid configuration, such as a hinged or pivoted lid, or no lid may be provided.

The charging unit 101 may include a user interface such as display 108, which can be provided at any convenient location, such as in the position shown in Figure 1.

Figure 2 shows a cross sectional view of a portion of the aerosol provision device 100. The aerosol provision device 100 comprises a main housing 200. The main housing 200 defines a device body of the device 100. The device 100 defines a heating chamber 201. A receptacle 205 defines the heating chamber 201. An opening 203 is provided to provide access to the heating chamber 201. The receptacle 205 comprises a wall arrangement including a receptacle side wall 205a and a receptacle base 205b. The base 205b is at the distal end of the receptacle 205. A heating zone 201a is configured at least a portion of the article for heating.

A heating member 301 is provided in a portion of the main housing 200 and the heating member 301 extends or projects into the heating chamber 201. The heating member 301 may comprise a base portion 301a which may be located in a recess provided in a portion of the body of the device 100. The heating member 301 upstands in the heating chamber 201. The heating member 301 upstands from the distal end.

The heating member 301 comprises an elongate heating member in the form of a pin. The heating member 301 in other embodiments comprises other elongate configurations, such as a blade. The heating member 301 may be inserted, in use, into a distal end of an aerosol generating article 50 (refer to Figure 3) which is received within the heating chamber 201 in order to internally heat the aerosol generating article 50.

The housing comprises housing wall 200a. The housing wall 200a extends along the longitudinal axis of the aerosol provision device 100, surrounding the heating chamber 201. The housing wall 200a may, at least in part, define a receiving chamber of the aerosol provision device 100, as the volume which is enclosed within the wall 200a. A housing base 200b is at the distal end of the housing wall 200a. In the shown embodiment, the heating member 301 upstands from the housing base 200b. The heating member 301 protrudes through the receptacle base 205b. An aperture 206 is formed in the receptacle base 205b through which the heating member 301 protrudes. In embodiments, the heating member 301 is mounted to the receptacle base 205b. The heating member 301 upstands from the receptacle base 205b.

The aerosol provision device 100 further comprises a removal mechanism 204 which may be removably retained to the main housing 200 of the aerosol provision device 100. The removal mechanism 204 in embodiments is omitted. In embodiments, the housing wall 200a at least in part defines the receptacle 205. The removal mechanism 204 may be retained to the main housing 200 so that at least a portion of the removal mechanism 204 extends into the heating chamber 201. The removal mechanism 204 may comprise a longitudinal portion such as a peripheral wall portion 207a, which in the present embodiment is tubular, and a base wall portion 207b. The wall 207a may be a shape other than tubular, and may be any shape which encloses (e.g. encircles) and defines the heating chamber 201 there within.

In embodiments with the removal mechanism 204, the removal mechanism 204 defines the heating chamber 201. The removal mechanism 204 forms the receptacle 205. In embodiments in which the removal mechanism 204 is omitted, other features of the device 100 define the heating chamber 201, for example the housing side wall 200a and housing base 200b.

The base portion 207b has the aperture 206 through which the heating member 301 may project. In order to retain the removal mechanism 204 to the main housing 200, the removal mechanism 204 is pushed into engagement with the main housing 200 in the distal direction, i.e. towards the distal end of the main housing 200, until the removal mechanism 204 is able to move no further in the distal direction. In the following description, when the removal mechanism 204 is referred to as being “retained to” the main housing 200, this is when the removal mechanism 204 is engaged with the main housing 200, and can move no further in the distal direction.

Together, the peripheral portion 207a and the base portion 207b may define and enclose an article chamber for receiving, the aerosol generating article 50, as shown in Figure 3. The article chamber comprises an inner surface, which is configured to contact the aerosol generating article, the inner surface comprising a longitudinally extending portion which is provided by the tubular portion 207a, and an end portion which is provided by the base portion 207b. In embodiments, the article chamber and the heating chamber are the same. When the aerosol generating article 50 is received in the heating chamber, it may contact both the longitudinally extending portion of the inner surface, and the end portion of the inner surface. In particular, the article chamber (i.e. the peripheral portion 207a and the base portion 207b) may be configured to receive at least part of the aerosol generating article 50 which is in the form of rod which is longitudinally extending and cylindrical, such that the longitudinal axis of the article is parallel to (and optionally in line with) the longitudinal axis of the aerosol provision device 100 when received in the article chamber.

The article chamber may also be referred to as a receiving portion. When the removal mechanism 204 is retained to the main housing 200, in use, the article chamber of the removal mechanism 204 is arranged, at least partially, within the heating chamber 201. The heating member 301 may be arranged so as to project into the article chamber, through the aperture 206 provided in the base portion 207b of the removal mechanism 204. The removal mechanism 204 is therefore configured to receive at least a portion of the aerosol generating article in use.

In embodiments, the removal mechanism 204 may comprise a first magnet or a magnetisable material 208. The main housing 200 may comprise a second magnet or magnetisable material 209. In use, the removal mechanism 204 may be magnetically retained to the main housing 200 by the interaction of the first magnet or magnetisable material 208 and the second magnet or magnetisable material 209.

In embodiments, the removal mechanism 204 is fully detachable from the main housing 200. The removal mechanism 204 may be retained to the main housing 200 by a magnetic force of attraction between the first magnet or magnetisable material 208 and the second magnet or magnetisable material 209. The removal mechanism 204 may be detached from the main housing 200 by overcoming the magnetic force between the first magnet or magnetisable material 208 and the second magnet or magnetisable material 209. In embodiments, the removal mechanism 204 is removably retained to the main housing 200 by other means. For example, the removal mechanism 204 may be configured to be removably retained to the main housing 200 by an interference fit with the main housing.

The removal mechanism 204 may comprise an internal element (comprising the tubular portion 207a and a base portion 207b) and an outer cap portion 210, wherein when retained to the main housing 200 the outer cap portion 210 encapsulates (e.g. covers) at least a portion of the main housing 200, such as the wall 200a of the main housing. The tubular portion 207a, base portion 207b and outer cap portion 210 may comprise an integral (e.g. unitary) component (formed, for example, by moulding). Alternatively, the tubular portion 207a and base portion 207b may comprise a first component and the outer cap portion 210 may comprise a second separate component. The first and second components may then be secured together.

Figure 4 shows another aerosol provision system 40. The system 40 comprises a one-piece aerosol provision device 400 for generating aerosol from an aerosol generating material, and the aerosol generating article 50 comprising the aerosol generating material. The device 400 can be used to heat the aerosol generating article 50 comprising the aerosol generating material, to generate an aerosol or other inhalable medium which can be inhaled by a user of the device 400.

The device 400 comprises a housing 500 which surrounds and houses various components of the device 400. The housing 500 is elongate. The device 400 has an opening 504 in one end, through which the article 50 can be inserted for heating by the device 400. The article 50 may be fully or partially inserted into the device 400 for heating by the device 400.

The device 400 may comprise a user-operable control element 506, such as a button or switch, which operates the device 400 when operated, e.g. pressed. For example, a user may activate the device 400 by pressing the switch 406.

The device 400 defines a longitudinal axis 509 along which an article 50 may extend when inserted into the device 400. The opening 504 is aligned on the longitudinal axis 509.

Figure 5 shows a cross-sectional schematic view of the aerosol provision system 40. Features described with reference to Figure 5 in embodiments are applicable to embodiments described above. The aerosol provision device 400 comprises a power source 410, a controller 420 and a heating chamber 401, in which the aerosol generating article 50 is removeable received.

The one-piece device of Figure 5 shows the power source 410 aligned along the longitudinal axis of the heating chamber 401. In another embodiment of a one-piece aerosol generating device, the power source is aligned along a second longitudinal axis, parallel to the longitudinal axis of the heating chamber.

The heating member 301 comprises an elongate heating member in the form of a pin. The heating member 301 in embodiments comprises other elongate configurations, such as a blade. The heating member 301 is provided in the heating chamber. The heating member 301 of Figure 5 and the heating member 301 described above with reference to Figures 1 to 3, such that details described herein may be applied to each. The heating member 301 extends or projects into the heating chamber 401.

The heating member 301 may be inserted, in use, into a distal end of the aerosol generating article 50 which is received within the heating chamber 401 in order to internally heat the aerosol generating article 50.

The aerosol provision devices 100, 400 comprise a heating arrangement 300. The heating arrangement 300 comprises a heater. The heating member 301 acts as the heater. The heater comprises a heating element 350 (refer to Figure 6), such as a resistive heating coil, arranged to be actuated to heat the heating member 301.

The heating arrangement 300 is a resistive heating arrangement. The heater is a resistive heating heater. The heating element, such as a heating coil, as will be described below is a resistive heating element. In such arrangements the heating assembly comprises a resistive heating generator including components to heat the heating element via a resistive heating process. In this case, an electrical current is directly applied to a resistive heating element, and the resulting flow of current in the heating element, acting as a heating component, causes the heating element to be heated by Joule heating. The resistive heating element comprises resistive material configured to generate heat when a suitable electrical current passes through it, and the heating arrangement comprises electrical contacts for supplying electrical current to the resistive material. In embodiments, the heating element forms at least part of the resistive heating member itself. In embodiments the resistive heating element transfers heat to the heating member, for example by conduction. The provision of a resistive heating arrangement allows for a compact arrangement. Resistive heating provides an efficient configuration.

Figure 6 shows the heating member 301 for use in an aerosol provision device as described above. The heating member 301 acts as or forms at least part of a heater. The heating arrangement 300 comprises the heating member 301. The heating member 301 comprises an elongate housing 302 and the heating element 350. The elongate housing 302 is an elongate member defining a longitudinal axis.

The elongate housing 302 is formed from a thermally conductive material, such as aluminium. Other materials such as stainless steel may be used. The elongate housing may comprise a coating on its outer surface. The elongate housing 302 is configured to transfer heat from the heating element 350 to the heating zone 201a.

The elongate housing 302 has a base end 303 and a free end 304. The base end 304 mounts to the device body. A mount 305 at the base end 303 mounts the heating member 301. It will be understood that different mounting arrangements may be used, for example a fixing, moulding, and bonding including adhering. The mount 305 may be a separate component or may be integrally formed with the elongate housing 302.

A groove 302a or region of reduced cross sectional diameter may be provided in the elongate housing 302 towards the base end 303 of the elongate housing 302. As will be discussed in more detail below, a heating coil 351 is located within an inner void 308 of the heating member 301. The groove 302a or region of reduced cross sectional diameter may be located, for example, along the length of the elongate housing 302 at a longitudinal position which is intermediate a first longitudinal position corresponding to the longitudinal position of an end of the heating coil 351 closest to the base end 303 and a second longitudinal position corresponding to the longitudinal position where a base end of the elongate housing 302 attaches to, abuts or is otherwise secured to the mount 305.

It will be understood that the groove 302a or region of reduced cross sectional diameter reduces, restricts or diminishes the effect of heat conduction from the main body of the heating member 301 to the base end of the heating member 301 which is mounted to the mount 305. As a result, the flow of heat or thermal energy from the heating member 301 into the mount 305 is reduced. The groove 302a or region of reduced cross sectional diameter can therefore be considered as having the function of acting as a thermal break which reduces heat bleed from the heating member 301 into the mount 305 or more generally into a mounting point.

Further embodiments are contemplated (not shown) wherein more than one groove or region of reduced cross sectional diameter may be provided in the elongate housing to act as a thermal break. Although the groove 302a or region of reduced cross sectional diameter is shown in Figure 6 as comprising an annular recess, wherein the annular recess has a rectangular cross-sectional profile, other embodiments are contemplated wherein the annular recess may have a different cross-sectional profile such as, for example, a V-notch or W-notch. Further embodiments are also contemplated wherein one or more grooves or regions of reduced cross sectional diameter may be provided on an inner surface of the elongate housing 302.

The elongate housing 302 comprises a housing body 306. The housing body 306 is tubular. The housing body 306 comprises a bore 307. The bore 307 defines an inner void (also referred to as an inner cavity) 308 of the heating member 301. The inner void 308 extends longitudinally. In embodiments, the inner void 308 is at least partially filled, for example with a filler. In embodiments, the inner void 308 is completely filled, for example with one or more fillers and/or components. In embodiments, the inner void 308 defines an air gap. An inner surface 309 is defined on an inner side of the elongate housing 302. An open end 310 to the inner void 308 is provided at the base end 303.

The free end 304 of the elongate housing 302 extends towards the proximal end of the heating chamber. The free end 304 of the heating member 301 is closed. The inner void 308 does not extend through the free end 304. A tip 311 is provided at the free end 304. The tip 311 extends to an apex 312. Other shapes and configurations of the tip 311 may be provided, for example the tip 311 may define a planar surface.

The heating element 350 extends in the heating member 301. The heating element 350 extends in the elongate housing 302 in the longitudinal direction. The heating element 350 is received in the inner void 308. The heating element 350 extends between the base end 303 and the distal end 304. In embodiments, the heating element extends partially along the length of the inner void 308. In embodiments the heating element 350 extends to or beyond the open end 310.

The heating element 350 in embodiments comprises a heating coil 351. The heating coil 351 comprises a resistive member defining the heating coil 351. In embodiments the heating coil 351 comprises an electrically insulative coating, such as a ceramic, to electrically insulate the heating coil 351 from the elongate housing 302. The electrically insulative coating in embodiments is thermally conductive to provide for heat transfer from the heating element 350 to the elongate housing 302. In embodiments the electrically insulative coating is omitted. In embodiments, a separate electrically insulative arrangement, such as at least one of an electrically insulative member and an electrically insulative filler is provided. The electrically insulative member and electrically insulative filler in embodiments is thermally conductive to provide for heat transfer from the heating element 350 to the elongate housing 302.

The heating coil 351 is a resistive heating coil. The heating coil 351 is a helical coil. The heating coil 351 has a rectangular cross-sectional profile. It will be understood that other coil configurations are possible. In embodiments, the heating coil 351 has a circular cross-sectional profile. In embodiments, the heating arrangement 300 comprises two or more heating coils.

The heating arrangement 300 comprises electrical connection paths. The electrical connection paths extend from each end of the heating element 350. A base electrical connection path 352 extends from the distal end of the heating element 350. A return electrical connection path 353 extends from the proximal end of the heating element 350. The return electrical connection path overlaps the longitudinal extent of the heating element 350. The electrical connection paths 352,352 are integrally formed with the heating element 350, for example as a single wire. In embodiments, connectors connect the electrical connection paths 352,353 with the heating element 350. The heating coil 351 is formed from a resistive material, such as a nickel/chrome alloy such as nichrome 80/20 (80% nickel, 20% chromium), an iron/chrome/aluminium alloy or a copper/nickel alloy.

Figure 7 shows the heating member 301 for use in an aerosol provision device as described above according to various embodiments. The heating member 301 acts as or forms at least part of a heater i.e. heating arrangement 300. The heating member 301 comprises an elongate housing 302 and a heating element 350. The elongate housing 302 is an elongate member defining a longitudinal axis that extends in a longitudinal direction.

A heater for an aerosol provision device is disclosed comprising an elongate housing defining a longitudinal axis, a first heater coil located within the housing and a second heater coil located within the housing. The first heater coil and the second heater coil are non-coincident in the direction of the longitudinal axis.

According to various embodiments a heater for an aerosol provision device may be provided comprising two heater coils. The heater coils may occupy different volumes with an inner cavity of an elongate housing. According to various embodiments an opening may be provided in the side of the elongate housing. The two heater coils may be inserted into the inner cavity and conductive pins may be arranged down the side. The two heater coils may be heated separately, and a more uniform heating profile may be achieved across each heater coil.

As a result, the heater can be arranged to heat an aerosol generating article during use so as to provide an improved experience to a user.

The elongate housing 302 is formed from a thermally conductive material, such as aluminium. Other materials such as stainless steel may be used. According to another embodiment the housing 302 may be formed from a ceramic. The elongate housing may comprise a coating on its outer surface. The elongate housing 302 is configured to transfer heat from the heating element 350 to the heating zone 201a.

The elongate housing 302 has a base end 303 and a free end 304. The base end 303 mounts to the device body. A mount 305 at the base end 303 mounts the heating member 301. It will be understood that different mounting arrangements may be used, for example a fixing, moulding and bonding including adhering. The mount 305 may be a separate component or may be integrally formed with the elongate housing 302.

The elongate housing 302 comprises a housing body 306. The housing body 306 is tubular. The housing body 306 comprises a bore 307. The bore 307 defines an inner void 308 of the heating member 301. The inner void 308 extends longitudinally. In embodiments, the inner void 308 is at least partially filled, for example with a filler. In embodiments, the inner void 308 is completely filled, for example with one or more fillers and/or components. In embodiments, the inner void 308 defines an air gap. An inner surface 309 is defined on an inner side of the elongate housing 302. An open end 310 to the inner void 308 is provided at the base end 303.

The elongate housing 302 may be configured to provide access to the inner void 308 through a longitudinally extending surface of the housing body 306 during at least part of the manufacturing process of the heater 300.

The free end 304 of the elongate housing 302 extends towards the proximal end of the heating chamber. The free end 304 of the heating member 301 is closed. The inner void 308 does not extend through the free end 304. A tip 311 is provided at the free end 304. The tip 311 extends to an apex 312. Other shapes and configurations of the tip 311 may be provided, for example the tip 311 may define a planar surface.

The heating element 350 extends in the elongate housing 302 in the longitudinal direction. The heating element 350 is received in the inner void 308. The heating element 350 extends between the base end 303 and the distal end 304. In embodiments, the heating element extends partially along the length of the inner void 308. In embodiments, (at least one heater coil of) the heating element 350 extends to or beyond the open end 310.

The heating element 350 comprises a first heater coil 351a and a second heater coil 351 b. The first heater coil 351a is located within the housing 302 at a first position in the longitudinal direction. The second heater coil 351b is located within the housing 302 at a second position in the longitudinal direction. The first position and the second position are different (non-coincident), such that one of the first heater coil 351a and the second heater coil 351b extends in the longitudinal direction beyond the other (one of the coils occupies a position in the longitudinal direction that the other does not). According to various embodiments, the first heater coil 351a and the second heater coil 351 b are separated from one another in the longitudinal direction i.e. the first heater coil 351a and the second heater coil 351b do not overlap in the longitudinal direction.

The arrangement of two or more heater coils within an inner cavity of an elongate housing enables electrical connections to be made more easily to the heater coils whilst the heater is being assembled or manufactured. Furthermore, the arrangement facilitates novel heater geometries to be formed which along customised heating profiles to be obtained.

However, in other embodiments, the first heater coil 351a and the second heater coil 351 b may at least partially overlap in the longitudinal direction to a small degree. For example, the first heater coil 351a may overlap the second heater 351 b by less than 20%, less than 15%, less than 10%, less than 5%, or less than 1% of the longitudinal length of the first and/or second heater coil 351 a, 351b.

Providing a plurality of heater coils 351 (at least the first 351a and second 351 b heater coils) within the elongate housing 302 and having different positions in the longitudinal direction can allow the heater 300 to heat more uniformly compared to providing a single larger heater coil within the elongate housing 302. In this regard, plural smaller coils having different longitudinal positions may provide a heating element of the same overall size as a single larger coil. However, a smaller coil may be manufactured with higher uniformity compared to a larger coil (and/or a suitable uniformity can be achieved with lower complexity/cost), such that the overall uniformity in the temperature profile provided by a plurality of coils may be greater compared to the temperature profile provided by one larger coil.

In particular, the same effect providing a single long heater coil may be provided according to various embodiments by locating two heater coils 351 a, 351b within an inner cavity 308 of the elongate housing. Accordingly, various heating geometries can be formed by utilising two or more heater coils 351 a, 351 b. For example, each heater coil 351 a, 351b may have a length < 50% of the longitudinal length of the inner cavity 308. The first heater coil 351a and the second heater coil 351b may have the same configuration (i.e. shape and/or size) as each other. This can allow the heater 300 to be constructed using plural heater coils 351 that are produced to the same specification and/or tolerances thereby simplifying manufacturing. As a result, novel heater geometries can be formed using a single type of heater coil. This enables more complex heating profiles to be obtained whilst at the same time reducing manufacturing costs by utilising a single type of heater coil.

However, in other embodiments the first heater coil 351a and the second heater coil 351b may have different configurations. Heater coils having different configurations may be used to, for example, account for any variance in the shape of the elongate housing 302 along the longitudinal axis.

The first heater coil 351a may be radially aligned with the second heater coil 352b i.e. the first heater coil 351a and the second heater coil 352 may have the same corresponding positions in a radial direction that is perpendicular to the longitudinal direction. Providing the first heater coil 351a with a radial position that at least partially overlaps with a radial position of the second heater coil 352b can allow for the elongate housing 302 to be more uniformly heated. However, according to other embodiments the first heater coil 351a may be radially offset from the second heater coil 351b, for example the first heater coil 351a may have no coincident radial position with the second heater coil 351 b. Providing the first heater coil 351 a radially offset from the second heater coil 351b may allow for easier electrical access to the different coils.

According to various embodiments the heating element 350 may have two heater coils. However, in other embodiments the heating element 350 may comprise 3, 4, 5, 6, 7, 8, 9, 10 or > 10 heater coils. Each heater coil may comprise < 50%, < 40%, < 30%, < 20 % or < 10% of the internal length of the inner cavity.

A (or each) respective heater coil of the plurality of heater coils 351 (such as the first 351a and/or second 351b heater coil) may comprise a resistive member defining the heating coil. The heater coil (s) 351 may comprise an electrically insulative coating, such as a ceramic, to electrically insulate the heater coil(s) 351a from the elongate housing 302. The electrically insulative coating in embodiments is thermally conductive to provide for heat transfer from the heating element 350 to the elongate housing 302. In embodiments the electrically insulative coating is omitted. In embodiments, a separate electrically insulative arrangement, such as at least one of an electrically insulative member and an electrically insulative filler is provided. The electrically insulative member and electrically insulative filler in embodiments is thermally conductive to provide for heat transfer from the heating element 350 to the elongate housing 302. Heater coil(s) 351 of the heating element 350 may be resistive heater coil(s). The heater coil(s) 351 may be helical coil(s). The heater coil(s) 351 may have, for example, a rectangular cross-sectional profile or a circular cross-sectional profile. The heater coil(s) 351 may be formed from a resistive material, such as a nickel/chrome alloy such as nichrome 80/20 (80% nickel, 20% chromium), an iron/chrome/aluminium alloy, or a copper/nickel alloy.

The heater (heating arrangement) 300 may comprise electrical connection paths. The heater 300 may comprise separate electrical connection paths for each of the first heater coil 351a and the second heater coil 351b or the first heater coil 351a and the second heater coil 351b may share an electrical connection path. In embodiments where the first heater coil 351a and the second heater coil 351b share an electrical connection path, the distal end of one heater coil may have an electrical connection path to the proximal end of another heater coil.

The heater 300 may comprise separate electrical connection paths for the first and second heater coils 351 a, 351b. A base electrical connection path 370b may connect to a proximal end of the first heater coil 351a. A return electrical path 370a may connect to a distal end of the first heater coil 351a. A base electrical connection path 360a may connect to a proximal end of the second heater coil 351b. A return electrical path 360b may connect to a distal end of the second heater coil 351b. Embodiments are contemplated wherein the return electrical connection paths overlap the longitudinal extent of the heating element 350. The electrical connection paths may be integrally formed with the heating element 350, for example as a single wire. In embodiments, connectors may connect electrical connection paths with the heater coils 351 a, 351b.

An aerosol provision device may comprise a heater 300 as described above with reference to Figure 7 and a controller (e.g. control circuit/circuitry). The aerosol provision device may be configured to heat an aerosol generating article to generate an aerosol. The controller may be (configured) for controlling operation of the plurality of heater coils 351 (e.g. first heater coil 351a and second heater coil 351b). The controller may control the operation of the heater coils via electrical connection path(s) for the heater coils.

The controller may be arranged to control the first heater coil 351a independently of the second heater coil 351b. The controller may be arranged to control the first heater coil 351a to have a first heating profile and the second heater coil 351b to have a second different heating profile. The controller may be configured to control the first heater coil 351a and the second heater coil 351b in parallel with each other (i.e. at the same time). The controller may be configured to independently control the first heater coil 351a and the second heater coil 351b to provide a uniform temperature profile across the elongate housing 302. Controlling the first heater coil 351a independently of the second heater coil 351b may allow for an overall more uniform heating profile for the heating element 350. For example, the heater coils may be independently controlled to counteract an existing temperature gradient along the elongate housing 302. The heater coils may additionally or otherwise be independently controlled to take account of any differences in the coils and/or their positions (e.g. based on manufacturing tolerances). However, in embodiments this may also or instead allow for different heater coils to be operated (powered to provide heat) at different times or for a deliberately non-uniform heating profile for the heating element 350 to be provided.

The controller may comprise one or more temperature sensors. The temperature sensor(s) may measure a temperature of the elongate housing 302 and/or an aerosol generating article within the aerosol provision device. The controller may be configured to control the heater coils based on the temperature sensor(s). In an embodiment, there is a temperature sensor for each of the plurality of heater coils.

Figure 8(a) illustrates an embodiment wherein two heater coils 351 a, 351 b are located so as to be non-coincident in the direction of the longitudinal axis. The two heater coils 351 a, 351 b are co-axial. Figure 8(b) illustrates an embodiment wherein two heater coils 351 a, 351 b are located so as to be non-coincident in the direction of the longitudinal axis. The two heater coils 351 a, 351 b are arranged so as to be non co-axial. Figure 8(c) illustrates an embodiment wherein two heater coils 351 a, 351b are located so as to only partially overlap in the direction of the longitudinal axis by < 5%. Figure 8(d) illustrates an arrangement wherein two heater coils 351 a, 351b have different lengths and a smaller heater coil 351b is located within the volume of a larger heater coil 35a.

Figure 9 illustrates a method of manufacturing a heater for an aerosol provision device according to various embodiments. The method comprises providing an elongate housing defining a longitudinal axis extending in a longitudinal direction (step 901) and then locating a first heater coil within the housing at a first position in the longitudinal direction (step 902). The method further comprising locating a second heater coil within the housing at a second position in the longitudinal direction (step 903). According to various embodiments the first position is different to the second position i.e. the first heater coil and the second heater coil are arranged so as to be non-coincident in the direction of the longitudinal axis.

The method may further comprise accessing an inner void through a longitudinally extending surface of the housing to locate the first and/or second heater coils within the housing. This may allow for easier and/or more accurate positioning of the first and/or second heater coil. For example, the method may comprise inserting the first and/or second heater coil through a gap in a longitudinal side of the housing. A portion of the housing may be movable (e.g. slidable or rotatable) to open and/or close the gap.

A method of generating an aerosol is also disclosed comprising providing an aerosol provision device as described above, at least partially inserting an aerosol generating article comprising aerosol generating material within the aerosol provision device and activating the aerosol provision device.

In the above described embodiments, the heating arrangement is a resistive heating arrangement. In embodiments, other types of heating arrangement are used, such as inductive heating. The configuration of the device is generally as described above and so a detailed description will be omitted.

An inductive heating arrangement comprises various components to heat the aerosol generating material of the article via an inductive heating process. Induction heating is a process of heating an electrically conducting heating member (such as a susceptor) by electromagnetic induction. An induction heating arrangement may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor (heating member) suitably positioned with respect to the inductive element. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive element and the susceptor, allowing for enhanced freedom in construction and application.

In inductive heating heat is generated in the susceptor (heating member) whereas in resistive heating heat is generated in the coil(s) (heating element).

In embodiments, the heating member of the aerosol provision system is a part of the aerosol generating article, rather than being a part of the aerosol provision device. The heating element may be a resistive heating element, for example in the form of the resistive coil described above, which is provided as part of the aerosol generating article. Electrical connections may enable electric current to flow through the resistive heating element.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.