WO2024046869A1

WO2024046869A1 - Aerosol generating device

Info

Publication number: WO2024046869A1
Application number: PCT/EP2023/073263
Authority: WO
Inventors: Andrew Robert WALLACE
Original assignee: Imperial Tobacco Limited
Priority date: 2022-08-31
Filing date: 2023-08-24
Publication date: 2024-03-07

Abstract

An aerosol generating device comprising a heater housing and a consumable engagement component (102) located within the heater housing. The consumable engagement component comprises an inner wall (106) defining a receiving cavity (108). The receiving cavity is configured to house a heater and engage with a consumable, the consumable including an aerosol generating substrate for heating by the heater. The consumable engagement component further comprises an outer wall (114) located between the inner wall and the heater housing, the outer wall defining an insulating cavity (1116). The insulating cavity is located between the receiving cavity and the heater housing to provide thermal insulation between the receiving cavity and the heater housing. The inner wall and the outer wall are integrally formed from the same material.

Description

AEROSOL GENERATING DEVICE

This application claims priority from EP22193258.5 filed 31 August 2022, the contents and elements of which are herein incorporated by reference for all purposes.

FIELD

The present disclosure relates to an aerosol generating device.

BACKGROUND

A typical aerosol generating apparatus may comprise a power supply, an aerosol generating unit that is driven by the power supply, an aerosol precursor, which in use is aerosolised by heat generated using the aerosol generating unit to generate an aerosol, and a delivery system for delivery of the aerosol to a user.

A drawback with known aerosol generating apparatuses is that a portion of the heat generated using the aerosol generating unit may be lost to the environment. This may lead to reduced thermal efficiency, and lower power usage efficiency.

Despite the effort already invested in the development of aerosol generating apparatuses further improvements are desirable. There may be a need for improved design of aerosol generating apparatuses to improve the function of the aerosol generating apparatus, to enhance the user experience, and to simplify manufacture of the aerosol generating apparatus.

SUMMARY

The present disclosure provides an aerosol generating device comprising a heater housing and a consumable engagement component located within the heater housing, the consumable engagement component comprising an inner wall defining a receiving cavity, the receiving cavity configured to house a heater and engage with a consumable, the consumable including an aerosol generating substrate for heating by the heater and an outer wall located between the inner wall and the heater housing, the outer wall defining an insulating cavity, the insulating cavity located between the receiving cavity and the heater housing to provide thermal insulation between the receiving cavity and the heater housing, wherein the inner wall and the outer wall are integrally formed from the same material.

In this way, there may be reduced heat loss through the heater housing. This means that user experience may be enhanced, as the heater housing may be of a lower temperature, which may improve the user experience and or safe operation of the device. Further, the efficiency of the device may be improved since less heat is lost to the environment. Further, the manufacture of the aerosol generating device may be simplified. Further, the receiving cavity may allow for simple entry of a consumable into the device. Defining a cavity may mean delimiting a cavity. The inner wall may delimit the receiving cavity. The inner surface of the inner wall may delimit the receiving cavity. The outer wall may delimit the insulating cavity. The inner surface of the outer wall and the outer surface of the inner wall may together delimit the insulating cavity.

Integrally formed from the same material may include being formed together in a single mould. In some examples, the inner wall and the outer wall may be formed by injection moulding, transfer moulding or melt moulding.

In some examples, the consumable engagement component further comprises an insulation opening into the insulating cavity, the insulation opening connecting the insulating cavity to the ambient atmosphere. In other words, in some examples the insulating cavity is not fully enclosed. In this way, the manufacture of the aerosol generating device may be simplified. In particular, moulding of the consumable engagement component may be facilitated. For example, the mould from which the consumable engagement component may be formed may comprise a protruding element which creates the insulating cavity. The protruding element may be connected to another portion of the mould, creating the insulation opening. Furthermore, air has advantageous thermal insulation properties.

In some examples, the insulating cavity and the receiving cavity open towards opposite directions. In other words, in some examples the insulation opening and the consumable receiving opening face in opposite directions to one another, the consumable receiving opening being configured to receive the consumable therethrough. Opposite directions may be directions which are antiparallel to one another. Opposite directions may be directions which are approximately antiparallel to one another. In this way, the manufacture of the aerosol generating device may be simplified. In particular, moulding of the consumable engagement component may be facilitated.

In some examples, the inner wall is tapered. In other words, in some examples the inner wall is thicker at a first end of the inner wall than at a second end of the inner wall. The first end of the inner wall may be adjacent the consumable receiving opening. The second end of the inner wall may adjacent a base of the inner wall which is configured to engage with the device. In this way, the manufacture of the aerosol generating device may be simplified. In particular, the moulding of the consumable engagement component may be facilitated.

In some examples, the outer wall is tapered. In other words, in some examples the outer wall is thicker at a first end of the inner wall than at a second end of the outer wall. The first end of the outer wall may be the end closest to the consumable receiving opening. The second end of the outer wall may adjacent a base of the outer wall which is configured to engage with the device. In this way, the manufacture of the aerosol generating device may be simplified. In particular, the moulding of the consumable engagement component may be facilitated.

In some examples, the insulating cavity is tapered. In other words, in some examples the insulating cavity is wider at a second end of the insulating cavity than at a first end of the insulating cavity. The first end of the receiving cavity may be the end closest to the consumable receiving opening. The second end of the receiving cavity may be adjacent a base of the outer wall which is configured to engage with the device. In this way, the manufacture of the aerosol generating device may be simplified. In particular, the moulding of the consumable engagement component may be facilitated.

In some examples, the tapering of the insulating cavity is a result of the inner wall being tapered.

In some examples, the tapering of the insulating cavity is a result of the outer wall being tapered.

In some examples, the tapering of the insulating cavity is a result of both the inner wall and the outer wall being tapered.

In some examples, the receiving cavity is tapered. In other words, in some examples the receiving cavity is wider at a first end of the receiving cavity than at a second end of the receiving cavity. The first end of the receiving cavity may be adjacent the consumable receiving opening. The second end of the receiving cavity may adjacent a base of the inner wall which is configured to engage with the device. In this way, the manufacture of the aerosol generating device may be simplified. In particular, the moulding of the consumable engagement component may be facilitated.

In some examples, the tapering of the receiving cavity is a result of the inner wall being tapered.

In some examples, the direction along which the insulating cavity is tapered is opposite to the direction along which the outer wall is tapered. In some examples, the direction along which the insulating cavity is tapered is opposite to the direction along which the inner wall is tapered.

In some examples, the receiving cavity and the insulating cavity are longitudinally elongate along the same direction. The respective longitudinal axes of the receiving cavity and the insulating cavity may be aligned. In this way, the manufacture of the aerosol generating device may be simplified. In particular, the moulding of the consumable engagement component may be facilitated.

In some examples, the consumable engagement component and the heater housing comprise respective complementary interlocking elements. In other words, in some embodiments the consumable engagement component and the heater housing comprise respective elements which allow the consumable engagement component and the heater housing to be fixed together. In this way the manufacture of the aerosol generating device may be simplified.

In some examples, the consumable engagement component comprises interlocking grooves and the heater housing comprises complementary interlocking protrusions for interlocking with the interlocking grooves of the consumable engagement component.

In some examples, the consumable engagement component comprises interlocking protrusions and the heater housing comprises complementary interlocking grooves for interlocking with the interlocking protrusions of the consumable engagement component.

In some examples, the consumable engagement component is fixed within the heater housing with a screw. In some examples, the consumable engagement component is integrally formed from the same material. In this way, the manufacture of the aerosol generating device may be simplified. In particular, the moulding of the consumable engagement component may be facilitated.

In some examples, the aerosol generating device comprises a heater. The receiving cavity is configured to house the heater.

In some examples, the heater extends from a body of the device to protrude into the receiving cavity.

In some examples, the inner wall includes a heater-receiving aperture at a base of the inner wall through which the heater protrudes into the receiving cavity. The base of the inner wall may be configured to engage with an end of a consumable inserted into the receiving cavity. For example, the end of the consumable may abut the base of the inner wall, in use.

In some examples, the depth of the insulating cavity is approximately equal to the length of the portion of the heater which protrudes into the receiving cavity when the heater is housed within the receiving cavity. In this way, there may be reduced heat loss through the heater housing.

Approximately equal may mean that one value is greater than 70%, 71%, 72, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92, 93%, 94%, 95%, 96%, 97%, 98%, or 99% the size of the other value. Approximately equal may mean that one value is less than 100%, 99%, 98%, 97%, 96%, 95%, 94%, 93%, 92%, 91%, 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81 %, or 80% of the size of the other value.

Approximately equal may mean that one value is within 1 cm, 0.9 cm, 0.8 cm, 0.7 cm, 0.6 cm, 0.5 cm, 0.4 cm, 0.3 cm, 0.2 cm, or 0.1cm of the size of the other value.

In some examples, the depth of the insulating cavity is longer than the length of the portion of the heater which protrudes into the receiving cavity when the heater is housed within the receiving cavity. In this way, there may be reduced heat loss through the heater housing.

In some examples, the heater housing is the housing of a cap of the device. The consumable engagement component may form part of a cap of the device.

In some examples, the cap is movably coupled to the body. In this way, cleaning of the aerosol generating device may be facilitated.

In some examples, the cap is slidably coupled to the body.

In some examples, the inner wall and the outer wall are integrally formed from a thermoplastic material. In some examples, the inner wall and the outer wall are integrally formed from polyetheretherketone (PEEK). In this way, the consumable engagement component may be made from a thermally insulating material which is highly resistant to thermal degradation. In some examples, the inner wall may extend circumferentially around the circumference of the receiving cavity. In this way, a consumable inserted into the receiving cavity may be supported from all sides.

In some examples, the inner wall forms a receiving cavity with a tubular shape. In some examples, the shape of the inner wall may be a frustum.

In some examples, a cross sectional shape of the receiving cavity perpendicular to the longitudinal axis of the receiving cavity is approximately circular. An approximate circle may be a rounded shape wherein the smallest diameter is between 80% and 100% the size of the largest diameter. An approximate circle may be a rounded shape wherein the smallest diameter is between 90% and 100% the size of the largest diameter. An approximate circle may be a rounded shape wherein the smallest diameter is between 95% and 100% the size of the largest diameter.

In some examples, the shape of the receiving cavity is complementary to the shape of a consumable for insertion within the receiving cavity.

In some examples, the outer wall extends circumferentially around a circumference of the inner wall. In this way, there may be reduced heat loss through the heater housing.

In some examples, the insulation opening extends circumferentially around a circumference of the inner wall. In this way, the manufacture of the aerosol generating device may be simplified. In particular, the moulding of the consumable engagement component may be facilitated.

In some examples, the aerosol generating device is a heat-not-burn device which is configured to generate aerosol by a heat-not-burn process

The present disclosure provides a consumable engagement component for use in an aerosol generating device, the consumable engagement component comprising an inner wall defining a receiving cavity, the receiving cavity configured to house a heater and engage with a consumable, the consumable including an aerosol generating substrate for heating with the heater and an outer wall located adjacent the inner wall externally to the receiving cavity, the outer wall defining an insulating cavity, the insulating cavity located between the inner wall and the outer wall to provide thermal insulation to an external surface of the inner wall, wherein the inner wall and the outer wall are integrally formed from the same material.

In some examples, the consumable engagement component includes one or more of the features disclosed herein with reference to the aerosol generating device disclosed herein.

The present disclosure provides an aerosol generating system comprising an aerosol generating device, the aerosol generating device including one or more of the features disclosed herein. The aerosol generating system further comprises a consumable the consumable including an aerosol forming substrate for heating with a heater, and the consumable insertable into the receiving cavity of the consumable engagement component. The present disclosure provides a method of manufacturing an aerosol generating device, the aerosol generating device including one or more of the features disclosed herein, wherein the method includes manufacturing a consumable engagement component, the consumable engagement component including one or more of the features disclosed herein.

The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and/or proceeding examples may be combined in any suitable combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements.

Fig. 1 is a block system diagram showing an example aerosol generating apparatus.

Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1 , where the aerosol generating apparatus is configured to generate aerosol from a solid precursor.

Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2.

Fig. 4 is a cut away view of an example embodiment of a consumable engagement component.

Fig. 5 is a cut away view of an example embodiment of an aerosol generating device.

Fig. 6 is a perspective view of an example embodiment of a consumable engagement component.

DETAILED DESCRIPTION OF EMBODIMENTS

Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and/or methods described herein could be embodied differently and/or be practiced or carried out in various alternative ways.

Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art, and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification. Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and/or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.

The use of the term “a” or “an” in the claims and/or the specification may mean “one,” as well as “one or more,” “at least one,” and “one or more than one.” As such, the terms “a,” “an,” and “the,” as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.

The use of the term “or” in the present disclosure (including the claims) is used to mean an inclusive “and/or” unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. For example, a condition “A or B” is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

As used in this specification and claim(s), the words “comprising, “having,” “including,” or “containing” (and any forms thereof, such as “comprise” and “comprises,” “have” and “has,” “includes” and “include,” or “contains” and “contain,” respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an “ex post facto” benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase “in one embodiment,” “according to an embodiment,” and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to ‘an,’ ‘one,’ or ‘some’ embodiment(s) may be a reference to any one or more, and/or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to “the” embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.

The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by “or” may be used interchangeably: As used herein, an "aerosol generating apparatus" (or “electronic(e)-cigarette’) may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may add itionally/alternatively be referred to as a “smoking substitute apparatus”, if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible “smoking article” may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and/or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol generating apparatus may be controlled by an input device. The input device may be configured to be user-activated, and may for example include or take the form of an actuator (e.g. actuation button) and/or an airflow sensor.

Each occurrence of the aerosol generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an “activation” of the aerosol generating apparatus. The aerosol generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol generating unit of the apparatus for a variable amount of time, e.g. based on the strength/duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).

The aerosol generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.

As used herein, an "aerosol generating system" may be a system that includes an aerosol generating apparatus and optionally other circuitry/components associated with the function of the apparatus, e.g. one or more external devices and/or one or more external components (here “external” is intended to mean external to the aerosol generating apparatus). As used herein, an “external device” and “external component” may include one or more of a: a charging device, a mobile device (which may be connected to the aerosol generating apparatus, e.g. via a wireless or wired connection); a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

An example aerosol generating system may be a system for managing an aerosol generating apparatus. Such a system may include, for example, a mobile device, a network server, as well as the aerosol generating apparatus.

As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to/include a vapour. An aerosol may include one or more components of the precursor.

As used herein, a “precursor” may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and/or glycerine. The term “flavouring” may refer to a component that provides a taste and/or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.

As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.

As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.

As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.

As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.

As used herein, a “puff” (or "inhale" or “draw”) by a user may refer to expansion of lungs and/or oral cavity of a user to create a pressure reduction that induces flow through the flow path.

As used herein, an "aerosol generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol generating apparatus.

As used herein, a “heating system” may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion. The heating element may be referred to as a “heater”.

As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. With liquid or gel implementations of the precursor, e.g. an e-liquid, the consumable may be referred to as a “capsule” or a “pod” or an “e-liquid consumable”. The capsule/pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a “stick” or “package” or “heat-not-burn consumable”. In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

As used herein, an "information carrying medium" may include one or more arrangements for storage of information on any suitable medium. Examples include: a computer readable medium; a Radio Frequency Identification (RFID) transponder; codes encoding information, such as optical (e.g. a bar code or QR code) or mechanically read codes (e.g. a configuration of the absence or presents of cut-outs to encode a bit, through which pins or a reader may be inserted).

As used herein “heat-not-burn” (or “HNB” or “heated precursor”) may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).

Referring to Fig. 1 , an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and/or an electrical connection to an external power source. The apparatus 1 includes a precursor 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.

Electrical circuitry (not shown in figure 1 ) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.

In variant examples, which are not illustrated, the power supply 2 may be omitted since, e.g. an aerosol generating unit implemented as an atomiser with flow expansion may not require a power supply.

Fig. 2 shows an implementation of the apparatus 1 of Fig. 1 , where the aerosol generating apparatus 1 is configured to generate aerosol by a-heat not-burn process.

In this example, the apparatus 1 includes a device body 50 and a consumable 70.

In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62.

The electrical circuitry 56 may include a processing resource for controlling one or more operations of the body 50, e.g. based on instructions stored in the memory 58. The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

The other component(s) 62 may include an actuator, one or more user interface devices configured to convey information to a user and/or a charging port, for example (see e.g. Fig. 3).

The body 50 is configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 penetrates into the solid precursor 6 of the consumable. In use, a user may activate the aerosol generating apparatus 1 to cause the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the solid precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

Fig. 3 shows an example implementation of the aerosol generating apparatus 1 of Fig. 2.

As depicted in Fig. 3, the consumable 70 is implemented as a stick, which is engaged with the body 50 by inserting the stick into an aperture at a top end of the body 50, which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid precursor 6.

The consumable 70 includes the solid precursor 6 proximal to the body 50, and a filter distal to the body 50. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole. The solid precursor 6 may be a reconstituted tobacco formulation.

In this example, the at least one heating element 54 is a rod-shaped element with a circular transverse profile. Other heating element shapes are possible, e.g. the at least one heating element may be blade-shaped (with a rectangular transverse profile) or tube-shaped (e.g. with a hollow transverse profile).

In this example, the apparatus 1 includes a cap 51 . In use the cap 51 is engaged at a top end of the body 50. Although not apparent from Fig. 3, the cap 51 is moveable relative to the body 50. In particular, the cap 51 is slidable and can slide along a longitudinal axis of the body 50.

The body 50 also includes an actuator 55 on an outer surface of the body 50. In this example, the actuator 55 has the form of a button.

The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and/or to indicate a charging state of the power supply 4. Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

The body 50 may also include an airflow sensor which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the consumable 70). This may be used to count puffs, for example.

In this example, the consumable 70 includes a flow path which transmits aerosol generated by the at least one heating element 54 to the mouthpiece of the consumable. In this example, the aerosol generating unit 4 is provided by the above-described heating system 52 and the delivery system 8 is provided by the above-described flow path and mouthpiece of the consumable 70.

The present disclosure provides an aerosol generating device 100 that comprises a consumable engagement component 102. Fig. 4 shows a cut-away view of an example embodiment of a consumable engagement component 102 which may be included in the aerosol generating device 100. The aerosol generating device 100 comprises a heater housing 104 (not shown in Fig. 4). An example of a heater housing 104 is shown in Fig. 5, as discussed below, within which the consumable engagement component 102 is located.

The consumable engagement component 102 comprises an inner wall 106 defining a receiving cavity 108. The receiving cavity 108 is configured to house a heater 54 and to engage with a consumable 70. In the embodiment shown in Fig. 6, the receiving cavity 108 is configured to house a heater 54 which protrudes through a heater receiving aperture 110 in the base of the inner wall 106, and the receiving cavity 108 is configured to engage with a consumable 70 by the shape of the receiving cavity 108 being complementary to the shape of a consumable 70 for insertion within the receiving cavity 108 (as discussed further below with reference to Fig. 9). A consumable 70 can be inserted into the receiving cavity 108 through a consumable receiving opening (not visible in the figures) in the consumable engagement component 102.

The consumable engagement component 102 further comprises an outer wall 114 located between the inner wall 106 and the heater housing 104 (not shown in Fig. 4, but an example of a heater housing 104 is shown in Fig. 5 as discussed below). The outer wall 114 defines an insulating cavity 116 which is located between the receiving cavity 108 and the heater housing 104. The insulating cavity 116 provides thermal insulation between the receiving cavity 108 and the heater housing 104. The insulation is provided around the receiving cavity 108. The insulating cavity 116 reduces heat passing from the receiving cavity 108 to the heater housing 104 when a heater 54 housed within the receiving cavity 108 is heating a consumable 70 engaged within the receiving cavity 108. Thus, the insulating cavity 116 reduces heat loss and restricts the heater housing 104 from heating up.

The inner wall 106 and the outer wall 114 are integrally formed of the same material. The integral formation of the inner wall 106 and the outer wall 114 facilitates the manufacture of the aerosol generating device 100. In this way, thermal insulation is provided around the receiving cavity 108 without a complex inner structure of the aerosol generating device or a separate thermal insulation component.

In the example embodiment shown in Fig. 4, the consumable engagement component 102 further comprises an insulation opening 118 into the insulating cavity 116. The insulation opening 118 connects the insulating cavity 116 to the ambient atmosphere. The presence of the insulation opening 118 allows the manufacture of the consumable engagement component 102 to be simplified, as open cavities may be easier to mould than closed cavities. Furthermore, the presence of air in the insulating cavity 116 provides a thermal insulating effect.

In the example embodiment shown in Fig. 4, the insulating cavity 116 and the receiving cavity 108 open towards opposite directions. In other words, the insulation opening 118 and a consumable receiving opening (not visible in the figures, but generally upwards in the figure) face in opposite directions to one another. In this way, the moulding of the consumable engagement component 102 is facilitated, as the removal of the mould (used to create the shape of the consumable engagement component 102) from the moulded consumable engagement component 102 is facilitated.

In the example embodiment shown in Fig. 4, the inner wall 106 is tapered. In this way, the moulding of the consumable engagement component 102 is facilitated, as the removal of the mould (used to create the shape of the consumable engagement component 102) from the moulded consumable engagement component 102 is facilitated.

In the example embodiment shown in Fig. 4, the outer wall 114 is tapered. In this way, the moulding of the consumable engagement component 102 is facilitated, as the removal of the mould (used to create the shape of the consumable engagement component 102) from the moulded consumable engagement component 102 is facilitated.

In the example embodiment shown in Fig. 4, the insulating cavity 116 is tapered. In this way, the moulding of the consumable engagement component 102 is facilitated, as the removal of the mould (used to create the shape of the consumable engagement component 102) from the moulded consumable engagement component 102 is facilitated. The tapering of the insulating cavity 116 is caused by the tapering of the inner wall 106 and the outer wall 114.

In the example embodiment shown in Fig. 4, the receiving cavity 108 is tapered. In this way, the moulding of the consumable engagement component 102 is facilitated, as the removal of the mould (used to create the shape of the consumable engagement component 102) from the moulded consumable engagement component 102 is facilitated. The tapering of the insulating cavity 116 is caused by the tapering of the inner wall 106 and the tapering of the outer wall 1 14.

In the example embodiment shown in Fig. 4 the receiving cavity 108 and the insulating cavity 116 are longitudinally elongate along the same direction. In this way, the moulding of the consumable engagement component 102 is facilitated, as the removal of the mould (used to create the shape of a consumable engagement component 102) from the moulded consumable engagement component 102 is facilitated.

In the example embodiment shown in Fig. 4, the consumable engagement component 102 comprises interlocking grooves 120a and interlocking protrusions 122a which allow the consumable engagement component 102 to be mechanically fixed within the heater housing 104, as is described in more detail below with reference to Fig. 5.

Fig. 5 shows a cut away view of a portion of an aerosol generating device 100 according to an example embodiment. The consumable engagement component 102 is located within a heater housing 104 of the aerosol generating device 100. In the example embodiment shown in Fig. 5, the heater housing 104 is the housing of a cap 51 of the device. In the example embodiment shown in Fig. 5, the aerosol generating device 100 comprises a heater 54 which extends from a body 50 of the device. The heater 54 is shown protruding through the heater receiving aperture 110 in the base of the inner wall 106 of the consumable engagement component 102.

In the example embodiment shown in Fig. 5, the cap 51 is slidably coupled to the body 50. A body engaging portion 124 of the cap 51 slides within a cap engaging portion 126 of the body 50. The cap 51 is slidable between an open position in which access is provided to the heater 54, and a closed position in which the cap 51 partially encloses the heater 54. In this way, a portion of the heater 54 can be accessed when the cap 51 is slid upwards away from the body 50, thus facilitating cleaning of the heater 54. Relative to the cap 51 , during the sliding movement the heater 54 moves through the heater receiving aperture 110.

In the example embodiment shown in Fig. 5, the depth of the insulating cavity 116 is approximately equal to the length of the portion of the heater 54 which protrudes into the receiving cavity 108. In this way, heat loss through the heater housing 104 is inhibited, as approximately the whole length of the heater 54 is surrounded by the insulating cavity 116.

In the example embodiment shown in Fig. 5, the consumable engagement component 102 and the heater housing 104 comprise respective complementary interlocking grooves 120a/b and interlocking protrusions 122a/b which allow the consumable engagement component 102 and the heater housing 104 to be mechanically fixed together. In this way the manufacture of the aerosol generating device 100 may be simplified.

In the example embodiment shown in Fig. 5, the consumable engagement component 102 is integrally formed from the same material. That is, the outer wall 114, the inner wall 106, and the interlocking grooves 120a/b and interlocking protrusions 122a/b are integrally formed from the same material. In this way, the manufacture of the consumable engagement component 102 is simplified. The consumable engagement component 102 is integrally formed from polyetheretherketone (PEEK) which is thermally insulating and highly resistant to thermal degradation.

Fig. 6 is a perspective view of an example embodiment of a consumable engagement component 102.

In the example embodiment shown in Fig. 6, the inner wall 106 forms a tubular shape extending circumferentially around the entire circumference of the receiving cavity 108 (not visible in Fig. 6), such that the cross section of the receiving cavity 108 taken perpendicular to the longitudinal axis of the receiving is approximately a circle. The tubular shape of the inner wall 106 is a frustum. A consumable 70 inserted into the receiving cavity 108 may be supported from all sides by the inner wall 106. The shape of the receiving cavity 108 is designed to be complementary to the shape of a consumable 70 for insertion within the receiving cavity 108.

In the example embodiment shown in Fig. 6, the outer wall 114 extends circumferentially around the entire circumference of the inner wall 106. In this way, heat loss may be reduced around the entire circumference of the receiving cavity 108. In the example embodiment shown in Fig. 6, the insulation opening 118 also extends circumferentially around the entire circumference of the inner wall 106. In this way, the moulding of the consumable engagement component 102 is facilitated.

In the example embodiment shown in Fig. 6, there are two longitudinal flattened sides 128a/b of the outer wall 114. In this way, the aerosol generating device may have smaller dimensions.

Claims

1. An aerosol generating device comprising: a heater housing; and, a consumable engagement component located within the heater housing, the consumable engagement component comprising: an inner wall defining a receiving cavity, the receiving cavity configured to house a heater and engage with a consumable, the consumable including an aerosol generating substrate for heating by the heater; and, an outer wall located between the inner wall and the heater housing, the outer wall defining an insulating cavity, the insulating cavity located between the receiving cavity and the heater housing to provide thermal insulation between the receiving cavity and the heater housing, wherein the inner wall and the outer wall are integrally formed from the same material.

2. The device of claim 1 wherein the consumable engagement component further comprises an insulation opening into the insulating cavity, the insulation opening connecting the insulating cavity to the ambient atmosphere.

3. The device of claim 2 wherein insulating cavity and the receiving cavity open towards opposite directions

4. The device of either of claims 2 or 3 wherein the insulating cavity is tapered.

5. The device of any of claims 2 to 4 wherein the receiving cavity and the insulating cavity are longitudinally elongate along the same direction.

6. The device of any of the preceding claims wherein the consumable engagement and the heater housing comprise respective complementary interlocking elements

7. The device of any of the preceding claims wherein the consumable engagement component is integrally formed form the same material.

8. The device of any of the preceding claims further comprising a heater.

9. The device of claim 8 wherein the heater extends from a body of the device to protrude into the receiving cavity.

10. The device of claim 9 wherein the depth of the insulating cavity is approximately equal to the length of the portion of the heater which protrudes into the receiving cavity when the heater is housed within the receiving cavity.

11 . The device of any of the preceding claims wherein the heater housing is the housing of a cap of the device.

12. The device of any of the preceding claims wherein the cap is movably coupled to a body of the device.

13. The device of any of the preceding claims wherein the inner wall and the outer wall are integrally formed from polyetheretherketone (PEEK).

14. A consumable engagement component for use in an aerosol generating device, the consumable engagement component comprising: an inner wall defining a receiving cavity, the receiving cavity configured to house a heater and engage with a consumable, the consumable including an aerosol generating substrate for heating with the heater; and, an outer wall located adjacent the inner wall externally to the receiving cavity, the outer wall defining an insulating cavity, the insulating cavity located between the inner wall and the outer wall to provide thermal insulation to an external surface of the inner wall, wherein the inner wall and the outer wall are integrally formed from the same material.

15. An aerosol generating apparatus comprising the aerosol generating device of any of claims 1 to 13 and a consumable, the consumable including an aerosol forming substrate for heating with a heater, and the consumable insertable into the receiving cavity of the consumable engagement component.