Aerosol Generating Device

Abstract

An aerosol generating device comprises: a tubular heating chamber comprising an opening arranged to receive a consumable; a heater comprising a heating region which extends over a portion of the total length of the tubular heating chamber, the heating region comprising a first end closest to the opening and an opposing second end; an elongate consumable arranged to be received such that it lies along the length of the heating chamber, the consumable comprising an aerosol substrate which extends over a portion of the total length of the consumable; and wherein the heating chamber and consumable are configured such that, when the consumable is received within the heating chamber, the first end of the heating region is aligned with a first end of the aerosol substrate such that the second end of the aerosol substrate extends beyond the second end of the heating region.

Description

BACKGROUND

The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers) has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos and rolling tobacco. Various devices and systems are available that heat or warm aerosolisable substances as opposed to burning tobacco in conventional tobacco products.

A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generating device or heat-not-burn device. Devices of this type generate an aerosol or vapour by heating an aerosol substrate that typically comprises moist leaf tobacco or other suitable aerosolisable material to a temperature typically in the range 150° C. to 300° C. Heating an aerosol substrate, but not combusting or burning it, releases an aerosol that comprises the components sought by the user but not the toxic and carcinogenic by-products of combustion and burning. Furthermore, the aerosol produced by heating the tobacco or other aerosolisable material does not typically comprise the burnt or bitter taste resulting from combustion and burning that can be unpleasant for the user and so the substrate does not therefore require the sugars and other additives that are typically added to such materials to make the smoke and/or vapour more palatable for the user.

In such devices, the aerosol substrate is typically included in a consumable that is held within a heating chamber and heated by a heater. The heater may be employed internally or externally to the chamber to provide the increased temperature to the heating chamber. Most commonly, such heating chambers are heated from the outside, with a conductive shell housing transferring the heat to the internal volume. Often the heater is arranged along the full length of the heating chamber to provide a large heating region, enabling the aerosol substrate to be heated quickly. One problem with such devices is that they may waste energy by heating unnecessary portions of the consumable. Another problem is that the aerosol substrate may become smaller after heating; becoming susceptible to being dislodged from the consumable and forming debris within the heating chamber. Such debris requires cleaning from the user in order to avoid a reduction in heating efficiency; as if the debris is not completely removed it creates an additional barrier for energy to be transferred through in subsequent heating sessions.

The present invention aims to make progress in addressing these issues by providing a device with a long lifetime that can efficiently heat an aerosol substrate.

SUMMARY

According to a first aspect of the invention, there is provided an aerosol generating device comprising a tubular heating chamber comprising an opening arranged to receive a consumable; a heater comprising a heating region which extends over a portion of the total length of the tubular heating chamber, the heating region comprising a first end closest to the opening and an opposing second end; an elongate consumable arranged to be received such that it lies along the length of the heating chamber, the consumable comprising an aerosol substrate which extends over a portion of the total length of the consumable wherein the length of the aerosol substrate is greater than the length of the heating region; and wherein the heating chamber and consumable are configured such that, when the consumable is received within the heating chamber, the first end of the heating region is aligned with a first end of the aerosol substrate such that the second end of the aerosol substrate extends beyond the second end of the heating region.

Aligning the heating region and aerosol substrate in this way provides evenly distributed heating along the length of the substrate. The heating region is prevented from extending beyond either end of the aerosol substrate in the length direction, ensuring that only the aerosol substrate is heated directly, rather than other unnecessary regions of the consumable. This reduces the energy wasted during operation of the device, thereby increasing the efficiency and battery life of the device. In addition, this configuration allows for a heater with a smaller component footprint to be used than those found in existing devices, enabling a more compact device design. Furthermore, limiting the heating region to the aerosol substrate of the consumable allows other components or regions to be included in the consumable while protecting them from the highest temperatures produced by the device.

Aligning the first end of the substrate and first end of the heating region ensures the aerosol substrate is directly heated without wasting energy heating non-substrate portions of the consumable, thereby increasing the efficiency of the device. Having the second end of the aerosol substrate extend beyond the heating region means that direct heating of the end region of the aerosol substrate is prevented, reducing shrinkage of this region of the substrate and ensuring that the aerosol substrate does not exit the consumable. This provides easier cleaning of the device as debris is not formed in the heating chamber.

The heating region refers to a region of the heater that, in use, is heated to a temperature sufficient to cause the aerosol substrate to release an aerosol. In some examples of the invention, the limits of the heating region may substantially correspond to the physical limits and dimensions of the heater. In other examples, the limits of the heating region may extend beyond the physical limits and dimensions of the heater. This could be a result of, for example, the power of the heater as a higher power heater may be able to heat a larger surrounding area to the target temperature than a lower power heater. As another example, a material with high thermal conductivity may be placed between the heater and aerosol substrate so as to control and extend the heating region beyond the heater component itself.

Due to this configuration, the length of the heating region is less than the length of the aerosol substrate.

As heat may be transferred, e.g. through conduction, from one area of the aerosol substrate to a different area of the aerosol substrate, in some examples of the invention the aerosol substrate may be sufficiently heated to generate the desired aerosol without requiring the heating region to extend along the full length of the aerosol substrate. This further reduces the energy required for operation of the device and allows for a smaller heater component to be implemented.

Moreover, this heating region-aerosol substrate configuration may prevent the aerosol substrate overheating while still providing sufficient heating to generate the desired aerosol.

In particular, the opening of the heating chamber may comprise an open end and the heating chamber comprises an opposing closed end.

The closed end of the heating chamber improves the heat insulation in the nearby region of the heating chamber. As the heating region and, in use, the aerosol substrate are arranged nearby the closed end, this further increases the heating efficiency of the device. In addition, the closed end may act as a limiting element, constraining the placement of the consumable within the heating chamber, that allows the heating region and aerosol substrate to be easily and consistently aligned in the desired configuration.

In particular, the closed end may comprise an indent extending into the heating chamber. In this way, the indent may act as a limiting element, holding the consumable in the bottom of the heating chamber, while leaving a gap for air to flow around and through the nearby portion of the consumable. Preferably, the indent is arranged at the centre of the closed end.

The heating region may extend along more than half of the length of the aerosol substrate from the first end of the aerosol substrate. This makes certain that an adequate area of the aerosol substrate is directly heated by the heater; providing fast, uniform and efficient heating and subsequent aerosol generation.

The heating region may extend along less than 90% of the length of the aerosol substrate from the first end of the aerosol substrate. This prevents direct heating of the second end of the aerosol substrate, reducing shrinkage of the nearby portion of the aerosol substrate and the probability of the aerosol substrate exiting the consumable and forming debris.

Preferably, the heating region may extend along ¾-⅞ of the length of the aerosol substrate from the first end. This provides an optimum balance between the above described benefits of efficient heating while preventing undesired shrinking of the aerosol substrate.

The second end of the aerosol substrate may be at an end of the consumable and the aligned first ends of the aerosol substrate and heating region are positioned at an intermediate position along the length of the consumable.

In this way, aerosol generated in the aerosol substrate portion of the consumable must travel through the full length of the consumable before being inhaled. This allows the aerosol to be altered, e.g. by cooling or the addition of flavouring, for a more pleasurable vaping experience.

The consumable may comprise an aerosol cooling region extending over a portion of the length of the consumable, the aerosol cooling region comprising a hollow tubular portion of the consumable.

In this way, the temperature of a generated aerosol may be accurately and consistently controlled before inhalation by a user. In addition, the aerosol cooling region allows for a smaller consumable and accommodating heating chamber as a generated aerosol is cooled (to the desired temperature for inhalation) over a shorter distance than would otherwise be possible.

The aerosol substrate may comprise tobacco.

The heater may be configured to heat the aerosol substrate to an elevated temperature to release an aerosol, without burning the consumable.

Preferably, the heater may be configured to heat the aerosol substrate to a maximum temperature between 150° C. to 350° C.

In particular, the opening of the heating chamber may comprise an open end and the heating chamber comprises an opposing closed end, wherein the heating chamber and consumable are configured such that, during use, air enters through the open end of the chamber and passes through an air channel between the heating chamber and consumable to reach the aerosol substrate.

In this way, air can flow around the consumable before being drawn through the aerosol substrate and consumable. When the heating chamber comprises the closed end, air flows into and out of the heating chamber though the opening.

Multiple air channels may be defined by protrusions extending from the heating chamber. In addition, these protrusions may be arranged to act as limiting elements and/or support a received consumable by abutting the surface of the consumable.

Preferably, the heating chamber and consumable are arranged such that the air channel passes the heating region so as to pre-heat the air before it reaches the aerosol substrate. In this way, air is pre-heated by the heater before it reaches the aerosol substrate; further increasing the heating efficiency of the device.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1A schematically illustrates an example aerosol generating device in an assembled configuration;

FIG. 1B schematically illustrates an example aerosol generating device with the internal components visible;

FIG. 2A schematically illustrates a first view of an example configuration of a heating assembly and consumable;

FIG. 2B schematically illustrates a second view of the example configuration of a heating assembly and consumable; and

FIG. 3 schematically illustrates a further example configuration of a heating assembly and consumable.

DETAILED DESCRIPTION

An example aerosol generating device 1 is generally illustrated in an assembled configuration in FIG. 1A. The device 1 comprises an outer housing 2 having a bottom portion and a top portion. The top portion of the housing 2 is provided with an aperture 7 through which an aerosol-generating consumable can be inserted into the device 1.

Within the housing 2, the device 1 comprises a heating assembly 3, a PCB 4 and a battery 5. FIG. 1B illustrates the example device 1 without the outer housing 2. The heating assembly 3 is operably connected to the PCB 4 and battery 5 to selectively provide power to the heating assembly 3 in order to heat it to a controlled temperature. The heating assembly 3, PCB 4, battery 5, and various other components of the device 1 are held in place within the housing 2 by a frame 6.

In use, a user holds the device 1 by the housing 2 and places a smokable, aerosol-generating consumable into, or near, the heating assembly 3 of the device 1 through the aperture 7. The device 1 is then operated by a switch or by a puffing action from the user to turn on the power supply from the battery 5 to the heating assembly 3, so as to heat the consumable at or near the heating assembly 3. Heat generated at the heating assembly 3 causes the consumable to heat and release vapours which form an aerosol. The user can then inhale the aerosol, either through the consumable itself or through the aperture 7 of the device 1.

An example heating assembly 3 with an elongate consumable 30 introduced is schematically illustrated in FIGS. 2A and 2B. FIG. 2A shows a side view of the heating assembly 3 and consumable 30 where FIG. 2B shows a cross-sectional view as indicated by the line A-A in FIG. 2A. The heating assembly 3 comprises a heater 20 and a tubular heating chamber 10 with an opening 12. In this example, the opening 12 is provided by an open end of the heating chamber 10. In some alternative examples of the device, the opening 12 may be arranged elsewhere on the heating chamber 10. The consumable 30 comprises an aerosol substrate 32 that extends over a portion of the length of the consumable 30. The aerosol substrate 32 is arranged at an end of the consumable 30 that is within the heating chamber 10 and furthest from the opening 12 of the chamber 10. The aerosol substrate 32 has a first end 32a and a second end 32b where, when correctly received within the heating chamber 10, the first end 32a is closer to the opening 12 than the second end 32b is.

The tubular heating chamber 10 comprises a closed end 14 opposing the opening 12 and side walls 16 extending between the opening 12 and the closed end 14 so as to define the internal volume of the heating chamber 10. The opening 12 is aligned with the aperture 7 such that, when the device 1 is fully assembled, the internal volume of the heating chamber 10 is accessible through the aperture 7 and opening 12.

In some examples of the invention, the device 1 comprises a collar 8 arranged to guide the consumable 30 into the heating chamber 10. This allows for easier insertion of the consumable 30 by a user and lowers the risk of damaging the consumable 30 during insertion. The collar 8 may be incorporated in a variety of configurations. For example, in FIG. 2 the top portion of the housing 2 comprises the collar 8 such that the collar 8 defines the aperture 7. In this example, internal diameter of the collar 8 and the internal diameter of the heating chamber 10 are substantially the same. Therefore, the collar 8 extends the internal volume of the heating chamber 10 and may be considered an extension of the heating chamber 10 such that the aperture 7 and opening 12 are the same.

The internal diameter of the collar 8 may vary along the length of the collar 8. In particular, the internal diameter of a portion of the collar 8 may decrease with proximity to the heating chamber 10 so as to provide a chamfered or bevelled edge. This further improves the user experience of inserting a consumable 30 into the heating chamber 10.

The heater 20 surrounds the heating chamber 10 and is configured to provide heat to the internal volume of the heating chamber 10. In particular, the heater 20 is a thin film heater wrapped around an outer surface of the heating chamber 10 to heat the side walls 16 of the chamber 10 and the internal volume. The heater 20 comprises a heating region 22; this is the region of the heating assembly 3 that, in use, is heated to a temperature sufficient to cause the aerosol substrate 32 to release an aerosol, without burning the consumable 30. For example, this may be the region defined by the region over which a heating element of the heater 20 extends. In other examples, the heating region 22 may extend beyond the physical limits and dimensions of the heater 20. In particular, the heater is configured to heat the aerosol substrate 32 to a maximum temperature between 150° C. and 350° C. The heating region 22 has a first end 22a and a second end 22b where the first end 22a is closer to the opening 12 of the heating chamber than the second end 22b is.

In this example, the thin film heater comprises a thin film circuit having resistive heating elements. The circuit, comprising the heating elements, is arranged to increase the surface area coverage of the heating elements across the wrapped surface of the chamber 10. The thin film heater can be wrapped around and held against the outer surface of the heating chamber 10 by a polyimide shrink wrap.

In other examples, the thin film heater can be affixed against the outer surface of the heating chamber 10 by other means, such as by use of temperature resistant adhesives. Arranging the heater 20 around the outer surface of the heating chamber 10 allows the consumable 30 to be heated while protecting the heater 20 from damage due to contact with the consumable 30.

In some examples of the invention, the heating assembly 3 further comprises a heater support 11 arranged to locate and support the heater 20 within the assembly 3. In FIG. 2, a portion of the heater support 11 is arranged between the collar 8 and the heating chamber 10. The internal diameter of this portion of the heater support 11 is substantially equal to the internal diameter of the heating chamber 10 such that the heater support 11 extends the internal volume of the heating chamber 10 and may be considered an extension of the heating chamber 10. In some other examples, the heater support 11 does not extend the internal volume of the heating chamber 10, and may be arranged away from the heating chamber 10 to provide support for the heater 20 from an alternative position.

As, in use, the heater support 11 and collar 8 are located away from the aerosol substrate 32, it is preferable that the heater support 11 and collar 8 both comprise materials that are good thermal insulators. This prevents heat generated by the heater 20 from being unnecessarily transferred to these components, further increasing the efficiency of the device. These may be the same thermally insulating materials of different thermally insulating materials.

As described above, the heating assembly 3 and the heater 20 in particular are connected to the PCB 4 and battery 5 when assembled within the device 1. The side walls 16 of the heating chamber 10, or at least the sections of the side walls 16 near the heating region 22, comprise a thermally conductive material, such as metal, to conduct heat from the heater 20 to the chamber 10.

The heating chamber 10 and consumable 30 are each configured so that, when the consumable 30 is received within the heating chamber 10, the aerosol substrate 32 and the heating region 22 are advantageously positioned relative to each other. More specifically, the substrate 32 and heating region 22 are aligned and the heating region 22 does not extend along the length of the aerosol substrate 32 beyond either end of the substrate 32. Aligning the heating region 22 and substrate 32 in this way provides an even heat distribution along the length of the substrate 32. Preventing the heating region 22 from extending beyond the ends of the aerosol substrate 32 reduces energy wasted being used to heat unnecessary areas of the consumable 30 or heating assembly 3. In addition, it also allows aerosol cooling regions to be established in other areas of the consumable 30 or heating assembly 3.

As shown in the example of FIG. 2A, the length of the heating region 22 is less that the length of the aerosol substrate 32 and the first end 22a of the heating region is aligned with the first end 32a of the aerosol substrate so that the second end 32b of the substrate extends beyond the second end 22b of the heating region. This allows the aerosol substrate 32 to be heated efficiently without directly heating the portion of the aerosol substrate 32 near the second end 32b. Thus, any decrease in the size of the substrate 32 near this end 32b is reduced along with the likelihood that portions of the substrate 32 will exit or be dislodged from the consumable 30 and form debris within the chamber 10.

More specifically, the first end 22a of the heating region is aligned with the first end 32a of the aerosol substrate and the heating region 22 extends along ¾ of the length of the aerosol substrate 32. Aligning the first ends 22a, 32a and extending the heating region 22 along more than half of the length of the aerosol substrate 32 provides fast, even, and efficient heating of the aerosol substrate 32 by the heater 20. Aligning the first ends 22a, 32a and extending the heating region 22 along less than 90% of the length of the aerosol substrate 32 prevents direct heating of the second end 32b of the aerosol substrate, reducing shrinkage of the nearby portion of the aerosol substrate 32 and the probability of the aerosol substrate 32 exiting the consumable 30 and forming debris. It has been determined that aligning the first ends 22a, 32a and extending the heating region 22 along ¾ to ⅞ of the length of the aerosol substrate 32 provides a desirable balance between these advantages.

The heating assembly 3 and/or the consumable 30 may comprise a limiting element to limit how far the consumable 30 can be inserted into the heating chamber 10. This ensures the heating region 22 and aerosol substrate 32 can be easily and consistently aligned in the desired configuration relative to one another. The limiting element may be, for example, a limiting portion of the consumable 30 with a diameter greater than the diameter of the opening 12 and/or aperture 7. Alternatively, the limiting element may be a limiting portion of the heating chamber 10 with a diameter less than the diameter of the consumable 30. The limiting means may also reversibly fix the consumable 30 in place while the device 1 is in use, or until the user deliberately removes the consumable 30 from the heating chamber 10.

The closed end 14 of the heating chamber 10 improves the heat insulation within the nearby internal volume of the chamber 10. As the heating region 22 and, when in use, the aerosol substrate 32 are arranged nearby to the closed end 14 this further increases the heating efficiency of the device 1. In addition, the closed end 14 may also act as a limiting element as described above.

While the example device 1 shown in FIGS. 2A and 2B comprises the heater 20 wrapped around the outer surface of the heating chamber 10, in another example the heater 20 may be provided on the interior of the heating chamber 10. Arranging the heater 20 in this manner may provide more efficient heating of a consumable as the heater 20 can directly heat the internal volume of the heating chamber 10, reducing energy lost through conduction to the side walls 16. Preferably, the heating chamber 10 comprises a thermally insulating material to further reduce heat loss.

In addition to the aerosol substrate 32, the consumable 30 comprises an aerosol cooling region 34 and a filter 36. The aerosol cooling region 34 extends over a portion of the length of the consumable 30 and comprises a hollow tubular portion 35 of the consumable 30. This hollow tubular portion 35 allows an aerosol (generated by heating the aerosol substrate 32) to pass through the consumable 30 without leaking through the sides of the hollow tubular portion 35. The aerosol cooling region 34 does not overlap with the heating region 22 so aerosol will not continue to be heated within the aerosol cooling region 34. In addition, the hollow tubular portion 35 may be configured to further accelerate heat loss within the aerosol cooling region 34. For example, by conducting heat away from the aerosol to other areas of the consumable 30. The length of the aerosol cooling region 34 and the dimensions of the hollow tubular portion 35 are configured such that, in use, a generated aerosol can be consistently provided within a desirable temperature range for inhalation by a user. In addition, a consumable 30 that includes an aerosol cooling region 34 can be provided with a shorter length than a consumable 30 without one as a generated aerosol is cooled to the desired temperature than would otherwise be possible. Consequently, a smaller heating chamber 10 is required to accommodate the shorter consumable 30.

The aerosol substrate 32 is arranged at an end of the consumable 30 that is within the heating chamber 10 and furthest from the opening 12. The filter 36 is arranged at the other end that is closest to the opening 12. The aerosol cooling region 34 extends along the length of the consumable 30 between the aerosol substrate 32 and the filter 36. This ensures that, in use, a generated aerosol may be sufficiently cooled before inhalation by a user. In other examples, the consumable 30 may not include the filter 36, or may further include additional components arranged throughout the consumable 30.

The consumable 30 and the heating chamber 10 are configured to define an air channel 40 between the consumable 30 and the heating chamber 10. Preferably, the heating chamber 10 also comprises the closed end 14. In use, i.e. when the user inhales an aerosol generated from the consumable 30, this allows air to enter the heating chamber 10 through the opening 12 and pass through the air channel 40, towards the closed end 14, to reach the aerosol substrate 32. The air channel 40 passes the heating region 12 and so provides a pre-heating effect on incoming air before it enters the consumable 30. This further increases the heating efficiency of the device 1, reducing the power required for operation.

Preferably, the closed end 14 of the heating chamber 10 comprises an indent 15. This can act as a limiting element, holding the consumable 30 in the bottom of the chamber 10, while leaving a gap for drawn air to flow through the end of the consumable 30.

In other examples, the consumable 30 and the heating chamber 10 are configured to define multiple air channels 40 between the consumable 30 and the heating chamber. For example, the heating chamber 10 may comprise protrusions 17 extending from the side walls 16 and arranged to abut the surface of the consumable 30 in order to support the consumable 30 while also providing the benefits associated with the air channels 40. Preferably, when the consumable 30 is received in the heating chamber 10, the protrusions 17 overlap with the aerosol substrate 40. The protrusions 17 may act as limiting elements as described above. The protrusions 17 shown in FIG. 2 are a series of longitudinal ribs whose longitudinal axis is substantially aligned with the longitudinal axis of the heating chamber. Alternatively, or in addition, the heating chamber 10 may comprise protrusions 17 differently shaped such as an array of small dots arranged to abut the surface of the consumable 30.

A further example of a heating assembly 3 with an elongate consumable 30 introduced is schematically illustrated in FIG. 3. Instead of a closed end 14, the heating chamber 10 in the example of FIG. 3 comprises an air inlet 19 arranged at the end of the heating chamber 10 furthest from the opening 12. This provides the heating assembly 3 with a straight air flow passage, as air can flow into the heating chamber 10 through the air inlet 19 (at one end of the heating chamber 10) and out of the heating chamber 10 at the opening 12 (at the other end of the heating chamber 10). In use, when a consumable 30 is received within the heating chamber 10, air may be drawn into the heating chamber 10 through the air inlet 19 and pass into the aerosol substrate 32. The air inlet 19 may also allow for easier cleaning of the heating chamber 10; for example, by forcing air through the heating chamber 10 when there is no consumable 30 received within.

The size of the air inlet 19 may be configured to control the rate of air flow through the heating chamber 10 during use. In the example of FIG. 3, the air inlet 19 has an internal diameter less than the internal diameter of the heating chamber and the external diameter of the aerosol substrate 32 portion of the consumable 30. In this way, the air inlet 19 allows air to pass into the heating chamber 10 while also acting as a limiting element as described above. In another example of the invention, the heating chamber 10 may comprise multiple air inlets 19 arranged at the end of the heating chamber 10. In such an example, this may provide further control of air flow through the heating chamber 10.

Preferably, when the heating chamber 10 comprises the air inlet 19, the opening 12 of the heating chamber 10 and the consumable 30 are configured such that, in use, the diameter of the opening 12 is substantially equal to the external diameter of the portion of the consumable 30 that is aligned with the opening 12. Such a configuration provides that, in use, air only enters into the heating chamber 10 through the air inlet 19. The consumable 30 and heating chamber 10 may still be configured to define an air channel 40 between the consumable 30 and the heating chamber 10 to allow air to directly reach a larger area of the aerosol substrate 32.

Definitions and Alternative Embodiments

It will be appreciated from the description above that many feature of the described embodiments perform independent functions with independent benefits. Therefore the inclusion or omission of each of these independent features from embodiments of the invention defined in the claims can be independently chosen.

The term “heater” should be understood to mean any device for outputting thermal energy sufficient to form an aerosol from the aerosol substrate 32. The transfer of heat energy from the heater 20 to the aerosol substrate 32 may be conductive, convective, radiative or any combination of these means. As non-limiting examples, conductive heaters may directly contact and press the aerosol substrate 32, or they may contact a separate component such as the heating chamber 10 which itself causes heating of the aerosol substrate 32 by conduction, convection, and/or radiation.

Heaters may be electrically powered, powered by combustion, or by any other suitable means. Electrically powered heaters may include resistive track elements (optionally including insulating packaging), induction heating systems (e.g. including an electromagnet and high frequency oscillator), etc. The heater 20 may be arranged around the outside of the aerosol substrate 32, it may penetrate part way or fully into the aerosol substrate 32, or any combination of these. For example, instead of the heater 20 of the above described embodiments, an aerosol generating device may have a blade-type heater that extends into an aerosol substrate in the heating chamber.

The aerosol substrate 32 may include tobacco, for example in dried or cured form, in some cases with additional ingredients for flavouring or producing a smoother or otherwise more pleasurable experience. In some examples, the aerosol substrate 32 such as tobacco may be treated with a vaporising agent. The vaporing agent may improve the generation of vapour from the aerosol substrate 32. The vaporising agent may include, for example, a polyol such as glycerol, or a glycol such as propylene glycol. In some cases, the aerosol substrate 32 may contain no tobacco, or even no nicotine, but instead may contain naturally or artificially derived ingredients for flavouring, volatilisation, improving smoothness, and/or providing other pleasurable effects. The aerosol substrate 32 may be provided as a solid or paste type material in shredded, pelletised, powdered, granulated, strip or sheet form, optionally a combination of these. Equally, the aerosol substrate 32 may be a liquid or gel. Indeed, some examples may include both solid and liquid/gel parts.

Consequently, the aerosol generating device 1 could equally be referred to as a “heated tobacco device”, a “heat-not-burn tobacco device”, a “device for vaporising tobacco products”, and the like, with this being interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices that are designed to vaporise any aerosol substrate.

As used herein, the terms “aerosol” and “vapour” are used interchangeably to refer to a suspension of particles or droplets of any size. Similarly, the term “vaporise” means to change, or cause the change into vapour and the term “aerosolise” means to make into an aerosol and/or to disperse into an aerosol.

Claims

1. An aerosol generating device comprising:

a tubular heating chamber comprising an opening arranged to receive a consumable;

a heater comprising a heating region which extends over a portion of a total length of the tubular heating chamber, the heating region comprising a first end closest to an opening and an opposing second end;

an elongate consumable arranged to be received such that it lies along the length of the heating chamber, the consumable comprising an aerosol substrate which extends over a portion of the total length of the consumable, wherein the a length of the aerosol substrate is greater than a length of the heating region; and wherein

the heating chamber and consumable are configured such that, when the consumable is received within the heating chamber, the first end of the heating region is aligned with a first end of the aerosol substrate such that a second end of the aerosol substrate extends beyond the second end of the heating region.

2. The aerosol generating device of claim 1, wherein:

the opening of the heating chamber comprises an open end and the heating chamber comprises an opposing closed end.

3. The aerosol generating device of claim 2, wherein the closed end comprises an indent extending into the heating chamber.

4. The aerosol generating device of claim 1, wherein the heating region extends along more than half of the length of the aerosol substrate from the first end of the aerosol substrate.

5. The aerosol generating device of claim 1, wherein the heating region extends along less than 90% of the length of the aerosol substrate from the first end of the aerosol substrate.

6. The aerosol generating device of claim 1, wherein the heating region extends along ¾-⅞ of the length of the aerosol substrate from the first end of the aerosol substrate.

7. The aerosol generating device of claim 1, wherein the second end of the aerosol substrate is at an end of the consumable and the aligned first ends of the aerosol substrate and heating region are positioned at an intermediate position along the length of the consumable.

8. The aerosol generating device according to claim 1, wherein the consumable comprises an aerosol cooling region extending over a portion of the length of the consumable, the aerosol cooling region comprising a hollow tubular portion of the consumable.

9. The aerosol generating device of claim 1, wherein the aerosol substrate comprises tobacco.

10. The aerosol generating device of claim 1, wherein the heater is configured to heat the aerosol substrate to an elevated temperature to release an aerosol, without burning the consumable.

11. The aerosol generating device of claim 10, wherein the heater is configured to heat the aerosol substrate to a maximum temperature between 150° C. and 350° C.

12. The aerosol generating device of claim 1, wherein the opening of the heating chamber comprises an open end and the heating chamber comprises an opposing closed end, wherein the heating chamber and the consumable are configured such that, during use, air enters through the open end of the chamber and passes through an air channel between the heating chamber and the consumable to reach the aerosol substrate.

13. The aerosol generating device of claim 12, wherein the heating chamber and the consumable are arranged such that the air channel passes the heating region so as to pre-heat the air before it reaches the aerosol substrate.