Aerosol Generation Device

Abstract

An aerosol generation device for generating an aerosol by heating a liquid aerosol substrate, the device comprising: a reusable section (200) comprising a heating element (210, 610); and a consumable (100) comprising the liquid aerosol substrate (110), wherein the consumable is adapted to supply the liquid aerosol substrate to the heating element in use, wherein the consumable or the reusable section comprises an aerosol generation chamber (120, 620), the aerosol generation chamber comprising a heater cradle (160) adapted to hold the heating element, the heater cradle comprising a first opening (161) adapted to receive the heating element into the heater cradle, and a capillary opening (162) adapted to draw the liquid aerosol substrate into the heater cradle in use.

Description

TECHNICAL FIELD

The present disclosure relates to devices for generating an aerosol which is inhaled by a user, such as electronic cigarettes. In particular, the disclosure relates to aerosol generation devices where the aerosol is generated by heating a liquid substrate.

BACKGROUND

Known aerosol generation devices often use a heating component, or heater, to heat an aerosol generating liquid in order to generate an aerosol, or vapour, for inhalation by a user. The heating component is typically made of a conductive material which allows an electric current to flow through it when electrical energy is applied across the heating component. The electrical resistance of the conductive material causes heat to be generated as the electric current passes through the material, a process commonly known as resistive heating.

In aerosol generation devices which use a liquid substrate, the liquid substrate is consumed and must be periodically supplied to the aerosol generation device. This is typically achieved by providing a consumable containing the liquid substrate.

A known type of consumable comprises both the liquid substrate and a heating element, such that the liquid substrate can remain inside the consumable when it is used to generate the aerosol. For example, this has the advantage that the liquid substrate is kept away from reusable components of the aerosol generation device such as a power source (e.g. battery), which are provided in a reusable section of the aerosol generation device is configured to cooperate with the consumable. Accordingly, when the consumable is replaced, the heating element is also replaced.

Such advanced heating elements may be more complex or expensive to manufacture, and it is desirable to avoid disposing of such heating elements when the consumable is replaced. Accordingly, an object of the invention is to provide an aerosol generation device having a mesh-type heating element, in which the heating element is reusable.

SUMMARY

According to a first aspect, the present disclosure provides an aerosol generation device for generating an aerosol by heating a liquid aerosol substrate, the device comprising: a reusable section comprising a heating element; and a consumable comprising the liquid aerosol substrate, wherein the consumable is adapted to supply the liquid aerosol substrate to the heating element in use.

By providing a reusable section of the aerosol generation device comprising the heating element, the heating element can be used with a plurality of consumables to generate an increased amount of aerosol over its lifetime.

Additionally, the reusable section or the consumable comprises an aerosol generation chamber, the aerosol generation chamber comprising a heater cradle adapted to hold the heating element, the heater cradle comprising a first opening adapted to receive the heating element into the heater cradle, and a capillary opening adapted to draw the liquid aerosol substrate into the heater cradle in use.

By providing a heater cradle having a capillary opening, a structure may be provided for controlling supply of the liquid substrate to the heating element.

Optionally, the heating element comprises a mesh of electrically conductive fibres configured to transport liquid through the heating element by capillary action in use.

By providing a heating element that is capable of transporting liquid by capillary, the aerosol generation device can be simplified. Furthermore, heating efficiency may be improved by providing a mesh with a large surface area for contacting the liquid aerosol substrate.

Optionally, the reusable section further comprises an electrical power source connected to the heating element.

Optionally, in a first embodiment: the consumable comprises an aerosol generation chamber containing the liquid aerosol substrate and a consumable opening adapted to receive the heating element into the aerosol generation chamber; and the reusable section comprises a loading mechanism configured to position the heating element in the aerosol generation chamber.

By providing a consumable which is capable, in use, of receiving the heating element in its aerosol generation chamber, the heating element can be used to generate aerosol from multiple consumables, while retaining the advantage of keeping the liquid substrate in the consumable, separated from other reusable components of the aerosol generation device.

Optionally: the loading mechanism is adapted move between an open position and a closed position, the loading mechanism is configured to receive and hold the consumable in the open position, and the loading mechanism and the heating element are relatively arranged such that the heating element moves through the consumable opening as the loading mechanism moves from the open position to the closed position.

By providing a loading mechanism arranged such that the heating element moves through the consumable opening when the loading mechanism is operated, the heating element can be more effectively positioned in the aerosol generation chamber for generating the aerosol.

Optionally, the loading mechanism comprises a positioning element adapted to engage with a corresponding element on the consumable, such that the consumable is aligned to receive the heating element.

By providing a positioning element, the likelihood of damage to the consumable and/or the heating element by incorrect operation of the aerosol generation device is reduced.

Optionally, the consumable opening comprises a consumable seal.

By providing a seal on the consumable opening, the liquid aerosol substrate is inhibited from leaking through the consumable opening when the opening is not being used to position the heating element for aerosol generation.

Optionally, the heating element comprises a rigid leading portion adapted to break the consumable seal when the heating element moves through the consumable opening.

By providing a rigid leading portion on the heating element, the consumable seal can be made stronger without limiting the materials which can be used for the mesh of electrically conductive fibres in the heating element.

Optionally, the consumable seal comprises an elastomer configured to re-seal the consumable opening.

By providing an elastomer seal, the liquid aerosol substrate is inhibited from leaking through the consumable opening after the heating element has entered the aerosol generation chamber.

Optionally, the heating element comprises a closing portion adapted to close the consumable opening when the heating element is in the aerosol generation chamber.

By providing closing portion on the heating element, the liquid aerosol substrate is inhibited from leaking through the consumable opening after the heating element has entered the aerosol generation chamber.

Optionally, the first opening is the capillary opening.

By moving the heating element into the heater cradle through the capillary opening, the supply of liquid substrate to the heating element may be controlled in the heater cradle without constraining how the heater cradle is arranged in the aerosol generation chamber.

Optionally, the first opening is the consumable opening, and the heating element comprises a rigid leading portion adapted to break a capillary seal of the capillary opening when the heating element moves through the consumable opening.

By combining the first opening with the consumable opening, it becomes unnecessary for the heating element to move through the liquid substrate contained in the aerosol generation chamber before entering the heater cradle.

Optionally, the consumable comprises a plurality of electrical contacts adapted to supply power to the heating element when the heating element is in the aerosol generation chamber, and the reusable section comprises a plurality of electrical contacts adapted to supply power to the consumable.

By providing power to the heating element through the consumable, it becomes unnecessary to have direct electrical contacts from the reusable section to the heating element passing through the consumable opening. This may improve safety and reliability, for example by keeping the electrical contacts away from the liquid aerosol substrate.

Optionally, the reusable section comprises a plurality of electrical contacts adapted to supply power directly to the heating element when the heating element is in the aerosol generation chamber.

By providing power to the heating element directly from the reusable section, the consumable can be kept simple without requiring any electrical elements.

Optionally, in a second embodiment, the reusable section further comprises: an aerosol generation chamber, wherein the heating element is arranged in the aerosol generation chamber, wherein the reusable section is adapted to receive the liquid aerosol substrate from the consumable into the aerosol generation chamber.

By receiving the liquid substrate from the consumable into the reusable section, the heating element can be used with multiple consumables, so that a total amount of aerosol generated across the lifetime of the heating element can be increased.

Optionally, the reusable section is configured to compress the consumable in order to drive the liquid aerosol substrate into the aerosol generation chamber.

By compressing the consumable, the consumable can be kept sealed as far as possible. More specifically, the liquid aerosol substrate can be driven out of the consumable without the need to provide a mechanism for pressure equalization inside the consumable.

Optionally, the consumable comprises a weak spot or outlet for the liquid aerosol substrate.

By providing a weak spot or outlet on the consumable, the liquid substrate is directed and it is not necessary to seal the consumable within the reusable section before compressing the consumable.

Optionally, the reusable section comprises a piercing element arranged to pierce the consumable.

By providing a piercing element in the reusable section, usage of the consumable with the aerosol generation device can be simplified and wastage of liquid aerosol substrate due to user error can be reduced.

Optionally, the consumable comprises an inlet for air.

By providing an inlet for air, pressure within the consumable can be kept constant and the liquid aerosol substrate can be transferred into the aerosol generation chamber in the reusable section without deforming the consumable.

Optionally, the reusable section is adapted to drive air into the consumable, in order to drive the liquid aerosol substrate into the aerosol generation chamber.

By adapting the reusable section to drive air into the consumable, transfer of the liquid aerosol substrate from the consumable to the aerosol generation chamber can be controlled by the reusable section without deforming the consumable.

Optionally, the heating element is detachable from the reusable section.

With a detachable heating element, the heating element can be replaced if, for example, it becomes less effective due to gradual build-up of residue from heating the liquid aerosol substrate. Nevertheless, the heating element need not be replaced with the consumable whenever the liquid aerosol substrate is exhausted.

Optionally, the aerosol generation device comprises control circuitry configured to perform self-cleaning, wherein the control circuitry drives the heating element at a predetermined high power for a predetermined period in order to pyrolyse residue on the heating element.

By performing self-cleaning, a lifetime of the heating element can be extended, and replacement of the heating element and/or the entire reusable section may become unnecessary.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example, with reference to the drawings, in which:

FIG. 1A is a schematic cross-section of a consumable according to a first embodiment;

FIG. 1B is a schematic illustration of a first side of the consumable;

FIG. 1C is a schematic illustration of a second side of the consumable;

FIG. 2 is a schematic illustration of a reusable section of an aerosol generation device according to the first embodiment;

FIG. 3A is a schematic illustration of an aerosol generation device according to the first embodiment;

FIG. 3B is a schematic cross-section of the aerosol generation device;

FIG. 4A is a schematic cross-section of a consumable according to a second embodiment;

FIG. 4B is a schematic cross section of part of an aerosol generation device according to the second embodiment;

FIGS. 4C and 4D are schematic cross-sections of the aerosol generation device according to the second embodiment at planes 4C, 4D illustrated on FIG. 4B;

FIGS. 5A, 5B and 5C are schematic cross-sections of modifications of the second embodiment;

FIG. 6A is a schematic illustration of a reusable section of an aerosol generation device according to a third embodiment;

FIG. 6B is a schematic cross-section of an aerosol generation device according to the third embodiment;

FIG. 7A is a schematic illustration of a reusable section of an aerosol generation device according to a fourth embodiment; and

FIG. 7B is a schematic cross-section of an aerosol generation device according to the fourth embodiment.

DETAILED DESCRIPTION

In the figures, x-, y- and z-axes are used to indicate relatively-rotated viewpoints in different figures. This axis labelling has no further significance for the design of the embodiments.

FIG. 1A is a schematic cross-section of a consumable according to a first embodiment. The consumable 100 comprises liquid aerosol substrate 110 contained in an aerosol generation chamber 120. The liquid aerosol substrate 110 may, for example, comprise an aerosolisation agent and a flavourant or medicament.

In this embodiment, the consumable 100 has a generally cuboid shape, and the aerosol generation chamber is also cuboid. However, this is only a simple example, and any suitable shape can be used for the exterior of the consumable 100 and for the aerosol generation chamber. For example, the consumable may be approximately cylindrical.

FIG. 1B is a schematic illustration of the consumable from a perspective facing a first side 131 on the exterior of the consumable. As shown in FIG. 1B, the first side 131 comprises a consumable opening 140. The consumable opening 140 is adapted to receive a heating element (described later) wholly or partly into the aerosol generation chamber 120.

In this embodiment, the consumable opening 140 takes the form of a slot or keyway. More generally, the consumable opening 140 must be large enough and appropriately shaped for the heating element (described later) to pass through.

In this embodiment, the consumable opening 140 comprises a breakable seal (consumable seal 141). The seal 141 prevents the liquid aerosol substrate from leaking out of the consumable 100 and, in use, may be broken to allow the heating element to move through the consumable opening 140, wholly or in part.

The seal 141 may be configured to re-seal the consumable opening, for example after the heating element has moved through the consumable opening. This has the advantage that the consumable 100 does not leak through the consumable opening 140, even while the consumable is being used to generate aerosol in an aerosol generation device. This re-sealing may be embodied by forming the seal 141 from two strips of elastomer (e.g. rubber), which may be pushed apart to break the seal and which will subsequently return to their original sealed positions.

In this embodiment, the first side 131 is a long side of the cuboid consumable 100. However, more generally the consumable opening 140 may be on any surface that can be positioned to receive the heating element (described later). For example, on a cylindrical consumable, the consumable opening 140 may be on the curved surface or on one of the flat ends.

Additionally labelled in FIG. 1B are a second side 132 and a third side 133 on the exterior of the consumable. In the present cuboid example of the consumable, the second side 132 and third side 133 are adjacent to the first side 131. However, this is not required. For example, in a cylindrical consumable, the first, second and third sides 131, 132, 133 may be different regions of the curved face, or may be a combination of the curved face and the flat faces of the cylinder.

Illustrated on each of the second side 132 and third side 133 are two positioning elements 150 adapted to engage with a loading mechanism on a reusable section of an aerosol generation device (described later). The positioning elements may, for example, be physical structures such as flanges, indentations or protrusions, or may be other engagement means that can be attached to or embedded inside the consumable, such as magnets. In one specific example, the positioning elements 150 may be longitudinal ridges or grooves. It is advantageous to use two pairs of positioning elements 150 on two different sides 132, 133 of the consumable to securely engage with the loading mechanism. However, one or more positioning elements 150 on any side of the consumable can engage with the loading mechanism. Furthermore, in some embodiments, specific positioning elements 150 can be omitted, for example where the aerosol generation device is generally adapted to hold the exterior surface of the consumable.

FIG. 1C is a schematic illustration of the third side 133 of the consumable, illustrating the arrangement of positioning elements 150 in this embodiment.

FIG. 2 is a schematic illustration of the reusable section of the aerosol generation device according to the first embodiment. FIG. 3A is a schematic illustration of an aerosol generation device according to the first embodiment comprising the reusable section together with a consumable as previously described. FIG. 3B is a schematic cross-section of the aerosol generation device. These will be described together to avoid repetition.

The reusable section 200 comprises a heating element 210 and a loading mechanism 220.

The loading mechanism 220 is configured to control movement of the consumable 100 such that the heating element 210 is positioned in the aerosol generation chamber 120.

More specifically, the loading mechanism 220 may be adapted to move between an open position (as shown in FIG. 2) and a closed position (as shown in FIG. 3A). The loading mechanism 220 is arranged relative to the heating element 210 such that, when the loading mechanism 220 is holding a consumable 100 and the loading mechanism 220 moves from the open position to the closed position, the heating element 210 moves through the consumable opening 140.

In the example shown in the figures, a hinge 222 is provided to control motion between the open position and the closed position. In this arrangement, the consumable 100 rotates as it is moved, and this must be considered in the design of the consumable opening 140 for allowing the heating element 210 into the aerosol generation chamber 120. Alternatively motion between the open position and the closed position may be a non-rotational motion guided by one or more straight rails. With the alternative arrangement, the size of the consumable opening 140 may be minimized to match a length of the heating element 210.

The loading mechanism 220 is configured to receive and hold the consumable 100 in the open position, in order to control motion of the consumable 100. Additionally, the loading mechanism 220 may be configured to ensure that the consumable opening 140 is aligned with the heating element 210. More specifically, the loading mechanism may comprise a corresponding positioning element 221 for each of the positioning elements 150 of the consumable 100, where each positioning element 221 is adapted to engage with the corresponding positioning element 150. For example, as shown in FIG. 3A, the positioning elements 221 and 150 may be interlocking structures. Alternatively, the positioning elements 221 of the loading mechanism 220 may, for example, be magnets similar to the positioning elements 150 of the consumable 100.

Additionally, in this embodiment, the reusable section 200 further comprises an electrical power source 230 connected to the heating element 210. The electrical power source 230 may for example be a battery. The reusable section 200 may further comprise control circuitry (not shown) for controlling the power supply to the heating element. The control circuitry may comprise a user interface such as a button or slider. Additionally, the electrical power source may be rechargeable, and the control circuitry may comprise an interface on the exterior of the reusable section 200, such as a USB interface, for supplying power to recharge the electrical power source 230.

In this embodiment, the reusable section 200 of the aerosol generation device is adapted to be held in a user's hand, and comprises a mouthpiece 240 for the user to inhale an aerosol generated by the assembled aerosol generation device.

The heating element 210 may be a metal wire or a fibre mesh array formed into different shapes, for example a coil wire. In such embodiments, in use the heating element is typically in contact or in close proximity to a wicking element that draws aerosol generating liquid from a reservoir or supply in the device to be vaporised. The wicking element commonly has a fibrous or porous structure which causes liquid to be drawn from the liquid supply by capillary action.

Some heating elements, in particular fibre mesh array heaters, combine the heating and wicking functions, where for example a sheet of electrically conductive porous material uses capillary action to draw the aerosol generating liquid from the reservoir into the heating component, which also provides heat when electrical energy is passed through it. The sheet of electrically conductive porous material can be shaped to optimise the synergy between heating and wicking functions.

In such embodiments, the heating element comprises a mesh 211 of electrically conductive fibres configured to transport liquid through the heating element by capillary action in use. In a typical example, the heating element has a width of approximately 7.5 to 8 mm, a depth of approximately 1.5 to 2 mm and the length of approximately 30 mm. The mesh 211 provides a wicking function to the heating element 210 and includes a fibre sheet of electrically conductive fibres. The fibre sheet may, for example, be formed in a square-wave or meandering arrangement. It should be understood that fibre sheet is a woven fabric, but the sheet can also be provided as a non-woven fabric, or a bundle of electrically conductive fibres. A plurality of slots may be provided in the mesh 211 to create the square-wave arrangement.

The heating element 210 additionally comprises a first contact 212 and a second contact 213. In use, electrical power is driven through the mesh 211 between the first and second contacts 212, 213 in order to provide resistive heating. In this embodiment, the first contact 212 and second contact 213 are also arranged as first and second supports for holding the mesh 211. In use, the electrical power is supplied from the electrical power source 230, through the first and second supports to the mesh 211.

The heating element 210 additionally comprises a rigid leading portion 214 adapted to break the consumable seal 141 of the consumable 100. This enables the heating element 210 to move through the consumable opening 140 of the consumable 100 without needing to adapt the mesh 211 to be sufficiently strong to break the seal 141, and therefore the mesh 211 can be optimized for its wicking and heating functions. The rigid leading portion 214 may, for example, be a solid blade of a material (e.g. metal) or may be a more rigid, thicker or denser portion of the mesh 211. Alternatively, the rigid leading portion may be a layered arrangement of two blades on either side of an extension of the mesh 211. Preferably, the rigid leading portion 214 is configured so that liquid can be wicked through the rigid leading portion 214 into the main body of the mesh 211, by including mesh or gaps in the rigid leading portion 214.

The heating element 210 further comprises a closing portion 215 adapted to close the consumable opening when the heating element is in the aerosol generation chamber. The closing portion 215 is particularly advantageous if the consumable seal 141 of the consumable 100 is not re-sealable, but may be omitted in other embodiments. The loading mechanism may be arranged to press the first side 131 of the consumable 100 against the closing portion 215 to create a seal. The closing portion 215 may comprise an absorbent material configured to absorb any liquid aerosol substrate that leaks through the consumable opening 140. In such absorbent examples, the closing portion 215 may also be replaceable.

FIGS. 3A and 3B illustrate the assembled aerosol generation device of the first embodiment, with a consumable 100 and a reusable section 200, and the heating element 210 positioned in the aerosol generation chamber 120.

As shown in FIG. 3A, as described above, the positioning elements 150 of the consumable 100 engage with the corresponding positioning elements 221 of the loading mechanism 220. Additionally, the first side 131 of the consumable 100 rests against the closing portion 215 of the heating element 210 to close the consumable opening 140.

FIG. 3A need not be a cross-section because, according to the present invention, the consumable 100 does not need to be enclosed completely within the reusable section 200 of the aerosol generation device, and the reusable section 200 may be open as shown. Alternatively, the reusable section 200 may form a closed box around the consumable 100 when the loading mechanism 220 is in the closed position.

FIG. 3B shows a cross-section through the consumable from the same viewpoint as FIG. 3A. In FIG. 3B, the first and second contacts 212, 213 extend through the consumable opening 140 into the liquid aerosol substrate 110 in the aerosol generation chamber 120, such that power can be supplied to the mesh 211 to generate aerosol or vapour within the aerosol generation chamber 120. The generated aerosol then directed to the mouthpiece 240. For example, the consumable 100 may comprise an air flow tube (not shown) arranged to connect through the reusable section 200 to the mouthpiece 240, where the air flow tube is arranged to receive the generated aerosol or vapour from the mesh 211 and mix the aerosol or vapour with air directed to the mouthpiece 240.

FIGS. 4A to 4D are schematic cross sections of part of an aerosol generation device according to a second embodiment. The second embodiment is similar to the first embodiment, except the consumable comprises a heater cradle 160. For simplicity, only the consumable 100 is shown in FIG. 4A, and much of the reusable section 200 is not shown in FIGS. 4B, 4C and 4D. The dashed lines 4B, 4C and 4D illustrate relative locations of each of the latter three cross-sections.

As shown in FIG. 4A, the heater cradle 160 is an enclosure within the aerosol generation chamber 120 surrounded by liquid aerosol substrate 110. Internally, the heater cradle 160 comprises an air flow channel 170, which is connected to the aerosol generation chamber 120 via a first opening 161 and a capillary opening 162. The first opening is aligned with the consumable opening 140 and is adapted to receive the heating element 210 into the heater cradle 160. The capillary opening 162 is adapted to draw the liquid aerosol substrate 110 into the heater cradle in use.

The heater cradle 160 may additionally comprise a first seal 163 and a capillary seal 164 arranged to prevent the liquid aerosol substrate 110 from entering the air flow channel 170 before the consumable 100 is used in an aerosol generation device. Alternatively, the first opening 161 and/or the capillary opening 162 may be sufficiently narrow, or the air pressure in the air flow channel sufficiently high to prevent the liquid aerosol substrate 110 from entering the air flow channel 170 before the consumable 100 is used.

Turning to FIGS. 4B, 4C and 4D, the heater cradle extends along an internal length of the aerosol generation chamber 120 parallel to the first side 131 of the consumable 100. This arrangement means that the heater cradle 160 is supported at each end where it meets the internal wall of the aerosol generation chamber 120, and means that the air flow channel 170 can be connected out of the consumable 100 to provide the generated aerosol to the mouthpiece 240 of the reusable section 200.

Additionally, as with the first embodiment, the first and second contacts 212, 213 of the heating element 210 extend into the aerosol generation chamber 120. In this embodiment, however, the heater cradle 160 is adapted to hold the heating element so that the wick 211 can generate the aerosol in the air flow channel 170. This is illustrated in cross-sections 4C and 4D, which are labelled in FIG. 4B, and are shown respectively in FIGS. 4C and 4D.

More specifically, in FIG. 4C, the first contact 212 is shown extending through the consumable opening 140, the liquid aerosol substrate 110, the first opening 161, the air flow channel 170, and partly into the capillary opening 162. In order to enter the consumable 100 and reach this position, the first contact 212 breaks the consumable seal 141, the first seal 163 and the capillary seal 164. The absence of seals 141, 163 and 164 is indicated in FIG. 4C using parentheses.

Similarly, in FIG. 4D, the mesh 211 is shown arranged in the air flow channel 170, extending partly into the first opening 161 and the capillary opening 162. In this position, the liquid aerosol substrate 110 can be drawn into the mesh 211 from the first opening 161 and the capillary opening 162 at a rate controlled by the sizes of the first opening 161 and capillary opening 162. In order to enter the consumable 100 and reach this position, the rigid leading edge 214 (not shown in this example) breaks the consumable seal 141, the first seal 163 and the capillary seal 164. However, after the mesh 211 has passed through the consumable opening 140, the consumable seal 141 may re-seal itself. The absence of seals 163 and 164 is indicated in FIG. 4D using parentheses.

By adding the heater cradle 160, the consumable 100 is simultaneously provided with an air flow channel 170 for extracting the aerosol and a means for controlling the supply of liquid aerosol substrate 110 to the mesh 211. Thus the efficiency of aerosol generation can be improved.

FIGS. 5A, 5B and 5C are schematic cross-sections of example modifications of the second embodiment. The modification of FIG. 5C may be combined with either of the modifications of FIGS. 5A and 5B.

The consumable illustrated in FIG. 5A is similar to the consumable of FIG. 4A, but there is only one opening in the heater cradle 160 of FIG. 5A. More specifically, the capillary opening 162 has been removed, and the first opening 161 performs the functions previously described for the capillary opening 162. This modification has the advantage that the rigid leading edge 214 does not need to provide a capillary wicking action because it passes all the way through the first opening 161 and thus cannot block the liquid aerosol substrate 110 from reaching the mesh 211. Additionally, this modification has the advantage that, with the removal of the capillary opening 162 and the associated reduction in volume of the heater cradle 160, the capacity for liquid aerosol substrate in the consumable is increased.

The consumable illustrated in FIG. 5B is similar to the consumable of FIG. 4A, except that the heater cradle 160 is connected directly to the consumable opening 140, and the first opening 161 has been removed. With this arrangement, the consumable seal 141 is not required, and the closing portion 215 can also be omitted. This is because the liquid aerosol substrate 110 can only enter the air flow channel 170 when 164 has been broken, i.e. when the heating element 210 has been positioned in the aerosol generation chamber. The heating element 210 will usually only be removed from the aerosol generation chamber after the liquid aerosol substrate 110 has been used up, so there is no point in normal usage of the consumable 100 at which there is a risk of leakage through the consumable opening 140.

The aerosol generation device illustrated in FIG. 5C is similar to the aerosol generation device of FIG. 4B, except that the first and second electrical contacts have been replaced with a plurality of electrical contacts adapted to supply power to the consumable. For example, a separate electrical interface 170, 270 may be provided between the consumable 100 and the reusable section 200. Additionally, the consumable 100 comprises a plurality of electrical contacts adapted to supply power to the heating element when the heating element is in the aerosol generation chamber. For example, when the heating element 210 is positioned inside the consumable 100, power may be supplied to the mesh 211 via the heater cradle 160. The first and second supports 212, 213 are still present but do not need to provide an electrical connection. This modification may improve safety and reliability because the electrical contacts no longer need to extend through the consumable opening 140 or the liquid aerosol substrate 110.

FIGS. 6A and 6B are schematic illustrations of a reusable section 200 and a consumable 100 of an aerosol generation device according to a third embodiment. The loading mechanism 220, electrical power source 230 and mouthpiece 240 of the third embodiment may be the same as the first or second embodiments, and only the differences from the preceding embodiments are described in detail.

The principle difference of the third embodiment from the previously described embodiments is that the heating element 610 is arranged within the aerosol generation chamber 620, and the aerosol generation chamber 620 is part of the reusable section 200 rather than the consumable 100. Accordingly, in this embodiment, the heating element 610 does not engage directly with the consumable 100.

As with previous embodiments, the heating element 610 comprises a mesh 211 and first and second electrical contacts 212, 213. However, because the heating element is fixed in the third embodiment, the rigid leading portion 214 and the closing portion 215 can be omitted. Additionally, in the third embodiment, the mesh 211 may simply extend between two ends of the aerosol generation chamber 620, such that supports 212, 213 can be replaced with simple electrical connections on the inner surface of the aerosol generation chamber 620.

In order to allow the heating element 610 to heat the liquid aerosol substrate 110, the reusable section 200 is adapted to receive the liquid aerosol substrate 110 from the consumable 110 into the aerosol generation chamber 620. More specifically, the reusable section 200 comprises a substrate channel 630 arranged to connect a consumable 100 to the aerosol generation chamber 620 and to allow the liquid aerosol substrate 110 to flow from the consumable 100 to the aerosol generation chamber 620.

The heating element 610 may additionally comprise a heater cradle 160 as previously described, to assist in controlling supply of liquid aerosol substrate 110 to the mesh 211.

The consumable 100 may be a consumable as described for the preceding embodiments. However, the consumable 100 need not be so complex for the third embodiment, and may simply comprise liquid aerosol substrate 110 contained in a casing.

As shown in FIG. 6A, the substrate channel 630 may comprise a piercing element 631 arranged to pierce the consumable 100, in order to form a fluid connection between the consumable 100 and the aerosol generation chamber 620. The piercing element 631 does not need to be integral with the substrate channel 630 and may instead, for example, be part of the loading mechanism 220. Additionally or alternatively, the consumable 100 may comprise a weak spot, valve or outlet on its outer surface to facilitate transfer of the liquid aerosol substrate 110 into the aerosol generation chamber 620.

Additionally, the reusable section 200 comprises a pressuring element 640 configured to compress the consumable 100 in order to drive the liquid aerosol substrate 110 into the aerosol generation chamber 620. As shown in FIG. 6A, the pressuring element 640 may be a simple as a plate mounted on one or more springs 641. The loading mechanism 220 may comprise a locking element, such as a latch, so that it can provide a reactive force for pressure on the consumable 100. By applying pressure in this way, the aerosol generating device can ensure that the liquid aerosol substrate 110 is transferred from the consumable 100 to the aerosol generation chamber 620 until the consumable 100 is substantially empty.

FIGS. 7A and 7B are schematic illustrations of a reusable section of an aerosol generation device according to a fourth embodiment. The fourth embodiment is similar to the third embodiment apart from taking a different approach to transferring the liquid aerosol substrate 110 from the consumable 100 to the aerosol generation chamber 620.

In the fourth embodiment, the reusable section 200 comprises an air channel 710 for allowing air to enter the consumable 100. The air channel 710 may comprise a piercing element 711 for creating an inlet 180 in the consumable 100 to allow air into the consumable 100 to replace the liquid aerosol substrate 110, and equalizing pressure in the consumable 100. Accordingly, the liquid aerosol substrate 110 can be transferred through the substrate channel 630 into the aerosol generating chamber 620 without requiring a pressuring element 640. The piercing element 711 may be omitted in some embodiments where the consumable 100 already comprises an inlet 180 for air, for example in the form of a one-way valve.

The air channel 710 may additionally be adapted to drive air into the consumable 100, in order to drive the liquid aerosol substrate 110 into the aerosol generation chamber 620. For example, the air channel 710 may comprise a pump 720.

Additionally or alternatively, a pump could be included in the substrate channel 630 in either of the third and fourth embodiments.

Further modifications are possible to decrease wastage of resources in the aerosol generation device.

In the above-described embodiments, the heating element 210, 610 is retained to be used with multiple consumables 100. However, the heating element 210, 610 may have a lifetime that is more limited than the reusable section. In order to avoid needing to replace the entire reusable section 200, the whole heating element 210, 610 or the mesh 211, may be detachable from the reusable section 200. With this configuration, the consumable 100 can be frequently replaced, and the heating element 210, 610 can be less frequently replaced, while the remainder of the reusable section 200 is used for its full lifetime.

Furthermore, one common reason for needing to replace the heating element 210, 610 is that it gradually builds up residue from heating the liquid aerosol substrate 110. This residue decreases the surface area of the mesh 211 and/or decreases the heating efficiency of the heating element 210, 610. In order to delay or eliminate the need to replace the heating element 210, 610, the aerosol generation device may be provided with control circuitry configured to drive the heating element 210, 610 in a self-cleaning mode. For example, the heating element 210, 610 may be driven at a maximum power or predetermined high power, for a predetermined period. By driving high power through the heating element 210, 610, the heating element may reach a temperature which is higher than during its normal aerosol-generating operation, and may be high enough to pyrolyse or otherwise remove residue from the heating element. The residue may then be drawn out in air flow through the mouthpiece or washed out of the aerosol generation device.

In the above described embodiments, the heating element comprises a mesh of electrically conductive fibres configured to transport liquid through the heating element by capillary action in use. However, this is not generally required for the invention. As an alternative to a mesh capable of providing a wicking function, the heating element 210 may comprise any other type of heating element.

The heating element may comprise a simple heating surface for supplying heat to the liquid aerosol substrate, for example using a ceramic heating element, metal plate and/or a planar resistive track. This may be combined with a separate wicking element or other flow channel for drawing the liquid aerosol substrate to the heating surface.

Furthermore, a more complex heating element may be used, such as an inductive heating element that is remote from a susceptor configured to provide heat to the liquid aerosol substrate.

Yet further, the heating element need not be an electric heating element. For example, the heating element may instead supply heat using a chemical reaction such as burning a fuel.

Claims

1. An aerosol generation device for generating an aerosol by heating a liquid aerosol substrate, the device comprising:

a reusable section comprising a heating element; and

a consumable comprising the liquid aerosol substrate,

wherein the consumable is adapted to supply the liquid aerosol substrate to the heating element in use,

wherein the consumable or the reusable section comprises an aerosol generation chamber, the aerosol generation chamber comprising a heater cradle adapted to hold the heating element, the heater cradle comprising a first opening adapted to receive the heating element into the heater cradle, and the heater cradle comprising a capillary opening adapted to draw the liquid aerosol substrate into the heater cradle in use.

2. An aerosol generation device according to claim 1, wherein the reusable section further comprises an electrical power source connected to the heating element.

3. An aerosol generation device according to claim 1, wherein:

the consumable comprises the aerosol generation chamber, and the aerosol generation chamber contains the liquid aerosol substrate and has a consumable opening adapted to receive the heating element into the aerosol generation chamber; and

the reusable section comprises a loading mechanism configured to position the heating element in the aerosol generation chamber.

4. An aerosol generation device according to claim 3, wherein:

the loading mechanism is adapted move between an open position and a closed position,

the loading mechanism is configured to receive and hold the consumable in the open position, and

the loading mechanism and the heating element are arranged with respect to one another such that the heating element moves through the consumable opening as the loading mechanism moves from the open position to the closed position.

5. An aerosol generation device according to claim 4, wherein the loading mechanism comprises a positioning element adapted to engage a corresponding element on the consumable, such that the consumable is aligned to receive the heating element.

6. An aerosol generation device according to claim 3, wherein the consumable opening comprises a consumable seal.

7. An aerosol generation device according to claim 6, wherein the heating element comprises a rigid leading portion adapted to break the consumable seal when the heating element moves through the consumable opening.

8. An aerosol generation device according to claim 1, wherein the first opening is the capillary opening.

9. An aerosol generation device according to claim 1, wherein:

the reusable section comprises the aerosol generation chamber,

the heating element is arranged in the aerosol generation chamber, and

the reusable section is adapted to receive the liquid aerosol substrate from the consumable into the aerosol generation chamber.

10. An aerosol generation device according to claim 9, wherein the reusable section is configured to compress the consumable in order to drive the liquid aerosol substrate into the aerosol generation chamber.

11. An aerosol generation device according to claim 10, wherein the consumable comprises a weak spot or an outlet for the liquid aerosol substrate.

12. An aerosol generation device according to claim 9, wherein the reusable section comprises a piercing element arranged to pierce the consumable.

13. An aerosol generation device according to claim 9, wherein the consumable comprises an inlet for air.

14. An aerosol generation device according to claim 13, wherein the reusable section is adapted to drive air into the consumable, in order to drive the liquid aerosol substrate into the aerosol generation chamber.

15. An aerosol generation device according to claim 1, wherein the heating element comprises a mesh of electrically conductive fibres configured to transport liquid through the heating element by capillary action in use.