WO2024094494A1

WO2024094494A1 - Aerosol provision device

Info

Publication number: WO2024094494A1
Application number: PCT/EP2023/079636
Authority: WO
Inventors: Tom Woodman; Juan Esteban Paz JAUREGUI; Mark Potter; Theodora NANNOU
Original assignee: Nicoventures Trading Limited
Priority date: 2022-10-31
Filing date: 2023-10-24
Publication date: 2024-05-10
Also published as: GB202216088D0

Abstract

An aerosol provision device is described. The device is configured to heat an article containing aerosol generating material. The device comprises a receptacle arranged to receive at least a portion of an article containing aerosol generating material. A heater comprising a housing protrudes in the receptacle to be received in at least a portion of an article and defines a free end and a base end. A heating element is in the housing. At least a portion of the free end of the housing comprises a different material to the remainder of the housing. Also provided is a heater for use in the aerosol provision device.

Description

AEROSOL PROVISION DEVICE

Technical Field

The present invention relates to an aerosol provision device, a heater for 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 an aerosol provision device configured to heat an article containing aerosol generating material, comprising: a receptacle arranged to receive at least a portion of an article containing aerosol generating material; a heater comprising a housing protruding in the receptacle to be received in at least a portion of an article and defining a free end and a base end; and a heating element in the housing, wherein at least a portion of the free end of the housing comprises a different material to the remainder of the housing.

The housing may comprise a housing body and a tip at the free end.

The housing body may be elongate.

The tip may comprise a different material than the housing body. The tip may comprise a material with a lower thermal capacity than the housing body.

The tip may comprise a material with a higher thermal capacity than the housing body.

The tip may have a lower thermal conductivity than the housing body. For example, the tip may comprise a material with a thermal conductivity of lower than 150W/mk, lower than 100W/mk, or lower than 75W/mk. For example, the tip may comprise silicon carbide. For example, the housing body may comprise at least one of one of aluminium and aluminium nitride.

The tip may have a higher thermal conductivity than the housing body. For example, the tip may comprise a material with a thermal conductivity of greater than 100W/mk, greater than 150W/mk, or greater than 200W/mk. For example, the tip may comprise aluminium nitride. For example, the housing body may comprise silicon carbide.

The material hardness of the tip may be greater than the material hardness of the housing body.

The tip may comprise a material hardness of greater than 500Kg/mm², greater than 1000Kg/mm², or greater than 1500Kg/mm² For example, the tip may comprise silicon carbide.

The material hardness of the tip may be less than the material hardness of the housing body.

The tip may comprise a material hardness of lower than 1500Kg/mm², lower than 1000Kg/mm², lower than 500Kg/mm², or lower than 200Kg/mm². For example, the tip may comprise aluminium nitride.

The tip may extend less than 20%, less than 15%, less than 10%, or less than 5% of the longitudinal extent of the housing.

The housing may comprise a coating.

The housing body may be tubular.

The housing body may comprise a bore.

The housing bore may define an inner void of the housing.

The inner void may extend through the housing body.

The inner void may extend longitudinally from the base to the free end.

The tip may comprise a tip wall defining a hollow region. A wall thickness of the tip wall may vary with distance from the base end.

An inner surface of the tip wall may include a strengthening rib.

The inner surface of the tip wall may comprise a plurality of strengthening ribs.

The tip may be integrally formed with the housing body.

The tip may be mounted with the housing body by at least one of welding, bonding, and affixing.

The tip may extend to an apex.

The tip may be one of conically, frusto-conically or cylindrically shaped.

The tip may define a planar surface.

The inner void may extend into the tip.

The inner void may define a hollow region in the tip.

The hollow region may be a filled hollow region.

The inner void may be at least partially filled.

The inner void may be entirely filled.

The inner void may define an air gap.

The housing may comprise an outer surface; at least a part of the outer surface may comprise a low friction material having a lower coefficient of friction than at least a portion of the outer surface.

The low friction material may have a lower coefficient of friction than at least one of a body outer surface of the housing body and a tip outer surface of the tip.

The article contact surface may have a coefficient of friction of less than 1.4, of less than 0.7, of less than 0.15, or of less than 0.10.

The low friction material may comprise one or more of a diamond-like-carbon (DLC), copper, glass, graphite, aluminium and aluminium magnesium boride (BAM).

The low friction material may be supported on the housing body and the tip.

At least 50%, at least 70%, or at least 80% of the area of the heater outer surface supports the low friction material.

The heater may be a resistive heating heater.

The heating element may be a coil.

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 a heater for an aerosol provision device configured to heat an article containing aerosol generating material, comprising: a heater housing defining a tip and a housing body; and a heating element in the housing; wherein at least a portion of the tip is formed from a different material than the housing body.

The heater housing may comprise a base end and a free end.

The heater may comprise a tip at the free end arranged to close the free end.

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.

According to an aspect, there is provided a system comprising the device 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 comprising a receptacle arranged to receive at least a portion of an article containing aerosol generating material, a heater comprising a housing protruding in the receptacle to be received in at least a portion of an article and defining a free end and a base end, and a heating element in the housing, wherein at least a portion of the free end of the housing comprises a different material to the remainder of the housing; 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; and

Figure 7 shows a schematic cross-sectional view of another heater of the device of Figure 1 or Figure 4.

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 electrical ly-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 (refer to Figure 2) 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 to receive 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.

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 401. 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.

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. 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. 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.

The elongate housing 302 comprises a housing body 306. The housing body 306 is elongate. 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 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. In embodiments, the tip 311 defines one of a pyramidical-shaped surface, a frusto- pyramidically shaped surface, and a dome-shaped surface. The tip extends less than 15% of the longitudinal extent of the housing. In embodiments, the tip extends less than 20%, less than 15%, less than 10%, or less than 5% of the longitudinal extent of the housing.

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 coil 351 is shown in cross-section in Figure 6. 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, such as a preformed 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 are integrally formed with the heating element, for example as a single wire. In embodiments, connectors connect the electrical connection paths 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.

The tip 311 extends from the housing body 306. The tip 311 is formed from a different material from the housing body 306. The tip 311 is formed from a first material and the housing body 306 is formed from a second material. The first material has a lower thermal capacity than the second material. Such an arrangement aids with thermal transfer to a portion of the article adjacent to the tip 311. In embodiments, the first material has a higher thermal capacity than the second material. Such an arrangement aids with limiting thermal transfer to a portion of the article adjacent to the tip 311 , for example if the tip is configured to penetrate through aerosol generating material of the article and into another portion of the article.

The tip 311 comprises a material of higher thermal conductivity than the housing body 306.

The tip 311 may have a higher thermal conductivity than the housing body. For example, the tip may comprise a material with a thermal conductivity of greater than 100W/mk, greater than 150W/mk, or greater than 200W/mk. For example, the tip may comprise aluminium nitride. For example, the housing body may comprise silicon carbide.

In embodiments, the tip 311 comprises a material of lower thermal conductivity than the housing body 306.

For example, the tip 311 may comprise a material with a thermal conductivity of lower than 150W/mk, lower than 100W/mk, or lower than 75W/mk. For example, the tip 311 may comprise silicon carbide. For example, the housing body 306 may comprise at least one of one of aluminium and aluminium nitride.

In embodiments, the material of the tip 311 may have a greater hardness that the material of the housing body 306. A greater hardness may be beneficial when the heating element 301 is inserted into an article containing aerosol material.

The material of the tip 311 may comprise, for example, one or more of boron nitride; carbon nitride; aluminium magnesium boride; diamond-like-carbon (DLC), and tungsten.

The tip 311 may comprise a material hardness of greater than 500Kg/mm², greater than 1000Kg/mm², or greater than 1500Kg/mm² For example, the tip 311 may comprise silicon carbide.

The material hardness of the tip 311 may be less than the material hardness of the housing body.

The tip 311 may comprise a material hardness of lower than 1500Kg/mm², lower than 1000Kg/mm², lower than 500Kg/mm², or lower than 200Kg/mm². For example, the tip may comprise aluminium nitride.

In embodiments, the tip 311 may comprise insulative material. The insulative material may be electrically insulating. In embodiments, the insulative material may be thermally insulating. In embodiments, the housing body 306 may alternatively or additionally comprise insulative material. The insulative material may be provided as a coating on the tip 311 and/or the housing body 306. The insulative material may contribute to limiting thermal transfer to specific portions of an article comprising aerosol generating material as required. In embodiments, the tip may penetrate though the aerosol generating material of an article and it may be desirable to limit thermal transfer to a different material in the article at the end close to the mouth end of the device.

In embodiments, the entire tip 311 is not comprised of a different material to the housing body 306. In embodiments, a portion of the free end 304 comprises a different material to the material of the remaining of the housing 302. The free end 304 of the housing 302 may comprise different material to part or whole of the rest of the housing 302. Such an arrangement may be beneficial to provide a heating arrangement that heats specific parts of an article comprising aerosol generating material.

Providing portions of the housing 302 comprising different materials to different parts of the housing 302 means that energy transfer can be adjusted. For example, in an embodiment where at least part of the tip 311 comprises a thermally insulating material, heat will not be directly transferred portions of the aerosol generating article 50 that are in contact with the tip 311. The article 50 will be more evenly heated.

In embodiments, the tip 311 may extend into the housing body 306. The interface between the tip 311 and the housing body 306 may not be defined by a change in shape of the components but rather a change in the materials comprised in each of the tip 311 and the housing body 306. In embodiments, the housing body 306 may extend into the tip 311. The elongate housing 302 may be integrally formed. The housing 302 may be formed during manufacture so that the housing body 306 and tip 311 are not separable.

In embodiments, the elongate housing 302 may be formed as a one-piece component. The housing body 306 and tip 311 may be separably formed in an initial step of manufacture. The housing body 306 and tip 311 may be formed together in a subsequent step and may not be separable following manufacture. The tip 311 may be mounted on the housing body 306 to form the elongate housing as a one-piece component. The tip 311 may be mounted by at least one of welding, bonding and affixing. Bonding includes adhering using an adhesive or other means. The mount fluidly seals the housing body 306 and tip 311. A separate sealing member may be provided.

In embodiments, the elongate housing 302 may be formed of separate components which are reversibly mounted and separable after manufacture. The housing body 306 and tip 311 may be formed separably during an initial step of manufacture and reversibly bonded using securing means or an adhesive.

In the embodiment shown in Figure 6, the inner void 308 does not extend into the tip 311. The tip 311 is a solid component.

The tip 311 has a lower thermal conductivity than the housing body 306. This contributes to limiting thermal transfer to a portion of the article adjacent to the tip 311.

Figure 7 shows another embodiment of the heating member 300 for use in an aerosol provision device. The heating member 301 is arranged substantially identically to the heating member shown in Figure 6. Accordingly, features discussed above are applicable to the embodiments described below, and vice versa.

In the embodiment shown in Figure 7, the inner void 308 extends partially into the free end 304. The free end 304 of the heating member 301 is closed. The tip 311 has a closed end. The tip extends to an apex 312 that defines the free end 304. The inner void 308 extends partially into the tip 311 towards the free end 304 but does not extend all the way though, that is the tip 311 defines the closed end of the housing 302.

The tip 311 comprises a tip wall 614 that defines a hollow region where the inner void 308 partially extends into the tip 311. The hollow region 616 is the portion of the inner void 308 that is arranged in the tip 311.

The wall thickness of the tip wall 614 may vary with distance from the base end 303. For example, the wall thickness may reduce with distance from the base end 303. The tip wall 614 may be thinnest at the point adjacent to the end of the hollow region 616. The end of the hollow region 616 is defined by the end of the inner void 308 closest to the free end 304. The tip wall 614 defines an inner surface 619 on an inner side of the tip wall 614.

The heating element may extend along the full longitudinal extent of the inner void 308. The heating element 350 may extend into the hollow region 616. In embodiments, the heating element 350 extends partially along the longitudinal length of the inner void 308. The heating element may not extend into the hollow region 616. In embodiments, the heating element 350 extends to or beyond the open end 310.

In embodiments, the inner surface 619 of the tip wall 614 may comprise a strengthening rib. The rib may be a circumferential rib that extends around the full circumference of the inner surface 619. The rib may be arranged at any circumference of the tip wall 614. In embodiments, the rib may project radially from the inner surface 619 into the hollow region 616. In embodiments, the inner surface 619 comprises a rib that extends longitudinally in the hollow region 616. It will be understood that a plurality of ribs may be provided. The plurality of ribs may comprise a mixture of circumferential, radial or longitudinal ribs. The ribs may strengthen the tip 311. Strengthening of the tip if beneficial to prevent shape changes or distortion when the heating member is inserted, in use, into an aerosol generating article 50.

The tip 311 may be conically shaped, as shown in Figures 6 and 7. Other configurations of the tip 311 may be provided. The tip 311 may define a planar surface. The tip may be, for example, one of conical, frusto-conical, and pyramidical in shape. The tip 311 may comprise a flat top. The tip 311 may define a dome. The tip may be at least substantially cylindrical. It will be understood that other suitable configurations of the tip may be provided.

The heating member 301 comprises an outer surface 320. At least part of the outer surface 320 may comprise a low friction material. At least part of the outer surface may comprise a low friction material having a coefficient of friction that is lower than at least a portion of the outer surface.

The low friction material may be supported on at least part of the outer surface 320 of the tip 311. The low friction material may be supported on at least part of the outer surface 320 of the housing body 306. The low friction material may be supported on at least part of both the tip 311 and the housing body 306. The low friction material may be supported on all of the outer surface 320 of the tip 311 and/or the housing body 306.

In embodiments, the low friction material may be provided as a coating on the outer surface 320. In embodiments, at least 50%, at least 70%, or at least 80% of the area of the heater outer surface supports the low friction material.

In embodiments, the article contact surface 313 has a coefficient of friction of less than 1.4, of less than 0.7 or of less than 0.15. The low friction material in embodiments forms the article contact surface 313. In embodiments, the low friction material is, for example, diamond-like-carbon (DLC). Other suitable materials include copper, glass, graphite, aluminium and aluminium magnesium boride (BAM). In embodiments, the low friction material comprises copper and one or both of the housing body 306 and tip 311 comprises glass. In embodiments, the low friction material comprises one of glass or diamond-like-carbon (DLC) and one or both of the housing body 306 and tip 311 comprises a metal, such as aluminium. In embodiments, the low friction material comprises aluminium and the main body of the housing 302 comprises a ceramic. Other combinations of materials are, however, envisaged. The provision of a low friction article contact surface aids with restricting one or more components of the article, such as glycerol adhering to the surface and diminishing the performance of the heater over time.

The housing body 306 and tip 311 may comprise combinations of materials such as, for example: copper and glass; or a metal, such as aluminium or aluminium magnesium boride (BAM) and glass. 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 (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.

Claims

1. An aerosol provision device configured to heat an article containing aerosol generating material, comprising: a receptacle arranged to receive at least a portion of an article containing aerosol generating material; a heater comprising a housing protruding in the receptacle to be received in at least a portion of an article and defining a free end and a base end; and a heating element in the housing, wherein at least a portion of the free end of the housing comprises a different material to the remainder of the housing.

2. The aerosol provision device of claim 1 , wherein the housing comprises a housing body and a tip at the free end.

3. The aerosol provision device of claim 2, wherein the tip comprises a different material than the housing body.

4. The aerosol provision device of claim 3, wherein the tip comprises a material with a lower thermal capacity than the housing body.

5. The aerosol provision device of claim 3, wherein the tip comprises a material with a higher thermal capacity than the housing body.

6. The aerosol provision device of any of claims 2 to 5, wherein the tip comprises a tip wall defining a hollow region.

7. The aerosol provision device of claim 6, wherein a wall thickness of the tip wall varies with distance from the base end.

8. The aerosol provision device of claim 6 or claim 7, wherein an inner surface of the tip wall includes a strengthening rib.

9. The aerosol provision device of any of claims 2 to 8, wherein the tip is integrally formed with the housing body.

10. The aerosol provision device of claim 9, wherein the tip is mounted with the housing body by at least one of welding, bonding, and a fixing.

11. The aerosol provision device of any of claims 2 to 10, wherein the housing comprises an outer surface; at least a part of the outer surface comprises a low friction material having a lower coefficient of friction than at least a portion of the outer surface.

12. The aerosol provision device of claim 11 , wherein the low friction material has a lower coefficient of friction than at least one of a body outer surface of the housing body and a tip outer surface of the tip.

13. The aerosol provision device of claim 12, wherein the low friction material is supported on the housing body and the tip.

14. The aerosol provision device of any of claims 11 to 13, in which at least 50%, at least 70%, or at least 80% of the area of the heater outer surface supports the low friction material.

15. The aerosol provision device of any of claims 1 to 14, wherein the heater is a resistive heating heater.

16. The aerosol provision device of any of claims 1 to 15, wherein the heating element is a coil.

17. A heater for an aerosol provision device configured to heat an article containing aerosol generating material, comprising: a heater housing defining a tip and a housing body; and a heating element in the housing; wherein at least a portion of the tip is formed from a different material than the housing body.

18. A system comprising the device according to any of claims 1 to 16 or the heater of claim 17, and an article comprising aerosol generating material.