Aerosol generator

Abstract

An aerosol generator for an article of use in an aerosol supply device is provided. The aerosol generator comprises: an aerosol generating material; and a resistive heating layer (40) comprising resistive heating elements (42). The resistive heating element is configured to heat at least a portion of the aerosol-generating material to generate an aerosol. The resistive heating element is at least part of an electrically conductive path between electrical contacts of a first type (44) and electrical contacts of a second type (46). The resistive heating layer includes a plurality of surface features (43a, 43b, 43c).

Description

Technical Field

[0001] This specification relates to an aerosol generator for an article used in an aerosol supply device. This specification also relates to a resistance heating device, such as an aerosol generator or consumable component of an aerosol generating device, an article used in an aerosol supply device, an aerosol supply system, and a method of forming an aerosol generator for an article used in an aerosol supply device. Background Technology

[0002] Aerosol generators have been developed for use in aerosol generating devices such as e-cigarettes, which release compounds without requiring combustion. Some exemplary aerosol generating devices include resistive heaters for generating aerosols. Further development of such devices is still needed. Summary of the Invention

[0003] The scope of protection sought by the various embodiments of the present invention is defined by the independent claims. Embodiments and examples (if any) described in this specification that are not within the scope of the independent claims should be interpreted as examples applicable to understanding the various embodiments of the present invention.

[0004] According to one aspect, an aerosol generator for an aerosol supply device is provided, the aerosol generator comprising: an aerosol generating material; and a resistance heating layer including a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; wherein the resistance heating element is at least a portion of a conductive path between a first type of electrical contact and a second type of electrical contact; and wherein the resistance heating layer includes a plurality of surface features.

[0005] In any of the above embodiments, the aerosol generating material is located on the resistive heating layer.

[0006] In any of the above embodiments, the plurality of surface features include a plurality of perforations.

[0007] In any of the above embodiments, the plurality of surface features includes at least one of a plurality of indentations and a plurality of protrusions.

[0008] In any of the above embodiments, at least some of the surface features are formed along the conductive path.

[0009] In any of the above embodiments, the plurality of surface features are configured to at least partially determine the resistance along the conductive path.

[0010] In any of the above embodiments, it includes an array of the surface features.

[0011] In any of the above embodiments, the surface features are regularly spaced in an array of surface features.

[0012] In any of the above embodiments, the aerosol generator includes an aerosol generating layer, which includes the aerosol generating material.

[0013] In any of the above embodiments, the aerosol generating layer includes a plurality of aerosol generating layer perforations.

[0014] In any of the above embodiments, the plurality of surface features of the resistive heating layer are aligned with the plurality of aerosol generating layer perforations.

[0015] In any of the above embodiments, the aerosol generating layer is non-perforated.

[0016] In any of the above embodiments, it includes a support member configured to support the resistive heating layer.

[0017] In any of the above embodiments, the support member includes a support layer.

[0018] In any of the above embodiments, the support member is electrically insulated.

[0019] In any of the above embodiments, the support includes at least one of paper and card.

[0020] In any of the above embodiments, the aerosol generating material is in direct contact with the resistive heating layer. In any of the above embodiments, the aerosol generating layer is in direct contact with the resistive heating layer.

[0021] In any of the above embodiments, the aerosol generating material is in indirect contact with the resistive heating layer. In any of the above embodiments, the aerosol generating layer is in indirect contact with the resistive heating layer.

[0022] In any of the above embodiments, the resistive heating layer and the support layer define a substrate.

[0023] In any of the above embodiments, the aerosol generator includes a laminate comprising the resistive heating layer and the support layer.

[0024] In any of the above embodiments, the layered compound includes the aerosol generating layer.

[0025] In any of the above embodiments, the support layer includes a card layer.

[0026] In any of the above embodiments, the support member is not perforated.

[0027] In any of the above embodiments, the support member includes a plurality of support perforations.

[0028] In any of the above embodiments, multiple surface features of the resistive heating layer are aligned with multiple support perforations.

[0029] In any of the above embodiments, the aerosol generating material is physically bonded to the support member.

[0030] In any of the above embodiments, the resistance heating layer is sandwiched between the support member and the aerosol generating material. In any of the above embodiments, the resistance heating layer is sandwiched between the support member and the aerosol generating layer.

[0031] In any of the above embodiments, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to both the length and the width, wherein the length is greater than or equal to the width, and wherein the width is greater than the depth.

[0032] In any of the above embodiments, the aerosol generating layer is a continuous aerosol generating layer.

[0033] In any of the above embodiments, the aerosol generating layer is a discontinuous aerosol generating layer.

[0034] In any of the above embodiments, the aerosol generating layer includes a plurality of discrete aerosol generating portions.

[0035] In any of the above embodiments, the resistive heating layer forms the first type of electrical contact.

[0036] In any of the above embodiments, the resistive heating layer forms the second type of electrical contact.

[0037] In any of the above embodiments, the aerosol generator includes a first type of electrical track extending from the heating element and including the first type of electrical contacts.

[0038] In any of the above embodiments, the first type of electrical contact is configured to be electrically connected to the device electrical connector.

[0039] In any of the above embodiments, the aerosol generator includes a second type of electrical track that extends from the heating element and includes the second type of electrical contacts.

[0040] In any of the above embodiments, the second type of electrical contact is configured to be electrically connected to the device electrical connector.

[0041] In any of the above embodiments, the resistance heating element is one of a plurality of resistance heating elements.

[0042] In any of the above embodiments, the resistive heating layer includes a plurality of heating elements, wherein each resistive heating element is at least a portion of the conductive path between a first type of electrical contact and a second type of electrical contact.

[0043] In any of the above embodiments, each resistance heating element includes multiple surface features.

[0044] In any of the above embodiments, each resistive heating element has the same resistance.

[0045] In any of the above embodiments, at least one of the resistive heating elements has a resistance different from that of the other resistive heating element.

[0046] In any of the above embodiments, each resistance heating element has the same plurality of surface features.

[0047] In any of the above embodiments, at least one of the resistive heating elements has a plurality of surface features that are different from those of the other resistive heating element.

[0048] In any of the above embodiments, at least one of the surface features of a resistive heating element has at least one of the size, number, and distribution of surface features that are different from those of another resistive heating element.

[0049] In any of the above embodiments, the first type of electrical contact and the second type of electrical contact enable current to be individually supplied to each of the plurality of heating elements.

[0050] In any of the above embodiments, one of the discrete aerosol generating portions is associated with a corresponding one of the plurality of resistive heating elements.

[0051] In any of the above embodiments, the aerosol generating layer includes at least one of dots, strips, and patches.

[0052] In any of the above embodiments, the resistive heating element is a first heating element and the resistive heating layer forms a second resistive heating element, each resistive heating element providing a conductive path for resistive heating of a portion of the aerosol generating material to generate an aerosol at the corresponding portion of the aerosol generating material.

[0053] In any of the above embodiments, the resistive heating layer forms a resistive heating element array that includes at least the first resistive heating element and the second resistive heating element.

[0054] In any of the above embodiments, each of the first type of electrical contact and the second type of electrical contact is configured such that current can be supplied to each of the resistive heating elements accordingly.

[0055] In any of the above embodiments, the aerosol generating layer includes a membrane or gel layer, which includes the aerosol generating material.

[0056] In any of the above embodiments, the aerosol generator includes a plurality of electrical contacts of the first type, wherein each of the heating elements includes separate electrical contacts of the first type.

[0057] In any of the above embodiments, the aerosol generator includes a plurality of the second type of electrical contacts, wherein each of the resistive heating elements includes separate second type electrical contacts.

[0058] In any of the above embodiments, the aerosol generator includes a single second-type electrical contact.

[0059] In any of the above embodiments, the single second-type electrical contact is shared among the resistive heating elements.

[0060] In any of the above embodiments, the resistive heating element is formed by at least one of the following operations: cutting the resistive heating layer; chemically etching the resistive heating layer; forming or pressing the resistive heating layer in the substrate; and printing the resistive heating layer.

[0061] In any of the above embodiments, the resistive heating layer is in the form of a foil.

[0062] According to one aspect, an aerosol generator is provided, comprising: an aerosolizable layer incorporating an aerosolizable material; and a conductive layer in contact with the aerosolizable layer, wherein the conductive layer includes a plurality of perforations, and wherein the conductive layer includes one or more heating elements, the heating elements or heating elements providing a conductive path for resistively heating a portion of the aerosolizable material to generate an aerosol, wherein the heating elements or heating elements extend from a first type of electrical connection to a second type of electrical connection. The aerosolizable layer may include a membrane or gel incorporating the aerosolizable material.

[0063] In any of the above embodiments, the conductive layer is formed as one or more heating elements. In any of the above embodiments, the conductive layer may be formed as multiple heating elements, each providing a conductive path for resistive heating of a portion of the aerosolizable material to generate vapor at a corresponding portion of the support.

[0064] In any of the above embodiments, the electrical connection allows current to be supplied individually to each of the plurality of heating elements (e.g., a plurality of positive electrical connections). In any of the above embodiments, each of the heating elements may have a separate first type of electrical connection. In any of the above embodiments, the aerosol generator includes a plurality of second type electrical connections (e.g., negative electrical connections). In any of the above embodiments, the aerosol generator includes a second type of single connection structure (e.g., a single negative electrical connection).

[0065] In any of the above embodiments, separate connection structures of the first type and the second type are provided for each heating zone, instead of using a common second type connection structure. In any of the above embodiments, the first type electrical connection is disposed on a first edge of the conductive layer, and the second type electrical connection is disposed on a second edge of the conductive layer. In any of the above embodiments, the first type and the second type electrical connections may be disposed on opposite sides of the region where the heating element is disposed. In any of the above embodiments, some or all of the first type and the second type electrical connections are disposed on the same edge of the conductive layer or on the second side of the region where the heating element is disposed.

[0066] In any of the above embodiments, the heating element can be formed by cutting the conductive layer (e.g., using a laser cutter).

[0067] In any of the above embodiments, the heating element may be formed by one or more of the following operations: chemically etching the conductive layer; forming or pressing the conductive layer in a substrate; and printing the conductive layer.

[0068] In any of the above embodiments, each heating element includes a non-straight conductive path (e.g., a tortuous or serpentine path) between the first electrical connection and the second electrical connection. In any of the above embodiments, the aerosolizable material includes a plurality of perforations. In any of the above embodiments, each heating element is a linear heating element, which includes a conductive path extending across the length of the aerosolizable layer. In any of the above embodiments, the conductive layer may be in the form of a foil. In any of the above embodiments, the conductive layer may be a metal layer (e.g., a metal foil, such as aluminum foil).

[0069] According to one aspect, an article of manufacture is provided, which may include an aerosol generator according to any of the embodiments described above.

[0070] In any of the above embodiments, the article is a consumable of the aerosol generation system.

[0071] According to one aspect, an aerosol supply device is provided, configured to receive an aerosol generator according to any of the embodiments described above.

[0072] According to one aspect, an aerosol supply system is provided, comprising: an aerosol generator according to any of the embodiments above; and an aerosol supply device configured to receive the aerosol generator or the article.

[0073] According to one aspect, a blank for forming an aerosol generator for an article of manufacture for an aerosol supply device is provided, comprising: a resistance heating layer wherein the resistance heating layer forms a heating element that provides a conductive path for resistance heating; a first type of electrical contact; and a second type of electrical contact; wherein the heating element extends between the first type of electrical contact and the second type of electrical contact, and wherein the resistance heating layer includes a plurality of surface features.

[0074] In any of the above embodiments, the plurality of surface features include a plurality of perforations.

[0075] According to one aspect, a method is provided, comprising: forming a resistive heating layer including a resistive heating element; forming an aerosol generating layer including an aerosol generating material on the resistive heating layer; wherein the resistive heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol; wherein the resistive heating element is at least a portion of a conductive path between a first type of electrical contact and a second type of electrical contact; and forming a plurality of surface features on the resistive heating layer.

[0076] According to one aspect, a method is provided, comprising: forming a resistive heating layer including a resistive heating element; disposing an aerosol generating material on the resistive heating layer; wherein the resistive heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol; wherein the resistive heating element is at least a portion of a conductive path between a first type of electrical contact and a second type of electrical contact; and forming a plurality of surface features on the resistive heating layer.

[0077] In any of the above embodiments, the plurality of surface features include a plurality of perforations.

[0078] According to one aspect, a method is provided, comprising: forming a conductive layer as one or more heating elements, the heating elements or heating elements providing a conductive path for resistively heating a portion of an aerosolizable material to generate an aerosol; and placing the formed conductive layer in contact with an aerosolizable layer, wherein the aerosolizable layer incorporates the aerosolizable material. The heating elements or heating elements extend from a first type of electrical connection to a second type of electrical connection. The conductive layer includes a plurality of perforations. The aerosolizable layer may include a membrane or gel incorporating the aerosolizable material.

[0079] In any of the above embodiments, forming the conductive layer may include forming the perforations. In any of the above embodiments, the method includes forming the perforations in the conductive layer before placing the formed conductive layer into contact with the aerosolizable layer. In any of the above embodiments, the method includes forming the perforations in the conductive layer after placing the formed conductive layer into contact with the aerosolizable layer. In any of the above embodiments, the method includes forming the perforations in the aerosolizable material.

[0080] In any of the above embodiments, the conductive layer is formed as a plurality of heating elements, each heating element providing a conductive path for resistive heating of a portion of the aerosolizable material to generate an aerosol at a specific portion of the aerosolizable layer. In any of the above embodiments, the equal electrical connection allows current to be supplied individually to each of the plurality of heating elements.

[0081] In any of the above embodiments, the method includes forming the heating elements at least partially by cutting the conductive layer (e.g., using a laser cutter). In any of the above embodiments, the method includes forming the heating elements at least partially by chemically etching the conductive layer. In any of the above embodiments, the method includes forming the heating elements at least partially by printing the conductive layer.

[0082] In any of the above embodiments, each heating element includes a non-straight conductive path (e.g., a tortuous or serpentine path) between the first electrical connection and the second electrical connection.

[0083] According to one aspect, an article is provided comprising an aerosol generator formed by any of the methods described in or according to any of the foregoing. The article may be a consumable in an aerosol generation system.

[0084] According to one aspect, a non-flammable aerosol generating apparatus is provided, configured to receive an aerosol generator, article, or consumable formed by any of the methods described in or according to any of the foregoing.

[0085] According to one aspect, a system is provided comprising: a non-flammable aerosol generating device according to any of the foregoing embodiments, and an aerosol generator, article, or consumable formed according to any of the foregoing embodiments or the methods described in any of the foregoing embodiments. The aerosol generator, article, or consumable may further include the equipment described in any of the foregoing embodiments.

[0086] According to one aspect, a kit is provided comprising: a non-flammable aerosol generating device of the fourth aspect, and an aerosol generator, article, or consumable formed according to any of the methods described in or according to any of the foregoing, wherein the aerosol generator is detachable from the non-flammable aerosol generating device. The kit may further include equipment described in any of the foregoing. The non-flammable aerosol generating device may include an integrated battery. Attached Figure Description

[0087] The following schematic diagrams will now be used to describe exemplary embodiments only, in which: Figure 1 Block diagram of an aerosol supply system; Figure 2 This is a block diagram of an aerosol generator; Figure 3 This is a block diagram of an aerosol generator; Figure 4 Showing the conductive layer; Figure 5 Showing the conductive layer; Figure 6 Demonstrating the heating element; Figure 7 Showing the conductive layer; Figure 8 Showing the conductive layer; Figure 9 Showing the conductive layer; Figures 10 to 13 A flowchart illustrating the processing logic; Figure 14 The aerosol generator is on display. Figure 15 Showing the formed conductive layer; Figures 16 to 18 A flowchart illustrating the processing logic; Figure 19 Showing the conductive layer; Figure 20 Showing the conductive layer; Figure 21 Part of the aerosol generator is shown. Figure 22 Connectors are shown for use in some embodiments; and Figure 23 This is a block diagram of an aerosol generation system. Detailed Implementation

[0088] As used herein, the term "delivery facility" is intended to encompass systems that deliver substances to users, and includes: A non-flammable aerosol supply system that releases compounds from an aerosolizable material without burning it; such systems include electronic cigarettes, tobacco heating products, and mixing systems that use combinations of aerosolizable materials to generate aerosols; and Articles comprising aerosolizable materials and configured for use in one of these non-flammable aerosol supply systems.

[0089] According to this disclosure, a "non-combustion" aerosol delivery system is an aerosol delivery system (or its components) in which the constitutive aerosol generating material delivers at least one substance to a user without combustion or ignition.

[0090] In some embodiments, the delivery system is a non-flammable aerosol supply system, such as an electrically powered non-flammable aerosol supply system.

[0091] In some embodiments, the non-flammable aerosol supply system is an electronic cigarette, also known as an electronic cigarette inhalation device or an electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not required.

[0092] In some embodiments, the non-flammable aerosol supply system is an aerosol generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

[0093] In some embodiments, the non-flammable aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to generate aerosols, one or more of which may be heated. The aerosol-generating materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the mixing system includes liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0094] Typically, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

[0095] In some embodiments, this disclosure relates to consumables that include aerosol-generating materials and are configured for use with a non-flammable aerosol supply device. Throughout this disclosure, these consumables are sometimes referred to as articles.

[0096] In some embodiments, a non-flammable aerosol supply system, such as its non-flammable aerosol supply device, may include a power source and a controller. The power source may be, for example, an electric power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon matrix that can be energized to distribute electricity in the form of heat to the aerosol generating material or a heat transfer material adjacent to the exothermic power source.

[0097] In some embodiments, a non-flammable aerosol supply system may include a region for receiving consumables, an aerosol generator, an aerosol generation region, a housing, a nozzle, a filter, and / or an aerosol modifier.

[0098] In some embodiments, consumables for use with a non-flammable aerosol supply device may include aerosol generating material, aerosol generating material storage area, aerosol generating material transfer assembly, aerosol generator, aerosol generating area, housing, covering, filter, nozzle and / or aerosol modifier.

[0099] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Where appropriate, any material may include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and / or one or more other functional materials.

[0100] In some embodiments, the substance to be delivered includes an active substance (sometimes referred to herein as an active compound).

[0101] The active substance used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be, for example, selected from health supplements, nootropics, psychoactive drugs, or digital drugs, or other technological / electronic devices that can induce physiological responses such as vagus nerve stimulation (VGS). The active substance may be naturally occurring or synthetically obtained. Active substances may include, for example, nicotine, caffeine, taurine, theophylline, vitamins such as B6 or B12 or C, and melatonin. Active substances may include one or more components, derivatives, or extracts of tobacco or another plant-based material. In one embodiment, the active substance is a legally permitted recreational drug.

[0102] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0103] As indicated herein, active substances may include or be derived from one or more plant-based medicinal materials or their components, derivatives, or extracts. As used herein, the term "plant-based medicinal material" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, outer skin, shells, or the like. Alternatively, materials may include naturally occurring active compounds found in plant-based medicinal materials or obtained synthetically. Materials may be in the form of liquids, gases, solids, powders, dust, crushed particles, fine particles, pellets, fragments, strips, flakes, or the like. Exemplary herbal ingredients include tobacco, eucalyptus, star anise, hemp, cocoa, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, cloves, cinnamon, coffee, anise, basil, bay leaf, white cardamom, coriander, fennel, nutmeg, oregano, and paprika. Ka), rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, holly, perilla, turmeric, Sichuan turmeric, sandalwood, coriander leaves, bergamot, orange blossom, myrtle, blackcurrant, valerian, peppermint, nutmeg bark, damien, marjoram, olive, lemon vanilla, lemon basil, chives, caraway, verbena, tansy, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint can be selected from the following varieties: wild mint (Mentha Arvensis), cultivated mint (Mentha cv), Egyptian mint (Mentha niliaca), Western mint (Mentha piperita), lemon mint cultivated variety (Mentha piperita citrata cv), Western mint cultivated variety (Mentha piperita cv), wrinkled green mint (Mentha spicata crispa), heart-shaped leaf mint (Mentha cardifolia), European mint (Mentha longifolia), variegated mint (Mentha suaveolens variegata), lip mint (Mentha pulegium), green mint cultivated variety (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0104] In some embodiments, the active substance includes or is derived from one or more plant-based medicinal materials or their components, derivatives or extracts, and the plant-based medicinal material is tobacco.

[0105] In some embodiments, the active substance includes or is derived from one or more plant-based medicinal materials or their components, derivatives or extracts, and the plant-based medicinal materials are selected from eucalyptus, star anise, cocoa and hemp.

[0106] In some embodiments, the active substance includes or is derived from one or more herbal medicines or their components, derivatives or extracts, and the herbal medicines are selected from rooibos tea and fennel.

[0107] In some embodiments, the substance to be delivered includes a flavoring agent.

[0108] As used herein, the terms "flavoring agent" and "seasoning agent" refer to materials that, where permitted by local regulations, can be used to produce a desired taste, aroma, or other sensory experience in products intended for adult consumers. These can include naturally occurring flavoring agents, herbal ingredients, extracts of herbal ingredients, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice / liquorice, hydrangea, eugenol, Japanese white magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, raspberries, cranberries, peach, apple, orange, mango, clementine, lemon, lime, tropical...). Fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, Scotch whisky, whiskey, gin, tequila, blue spirit, spearmint, peppermint, lavender, aloe vera, white cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, areca nut, hookah, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon, parsley ( Caraway), Cognac, Jasmine, Ylang-ylang, Sage, Fennel, Wasabi, Piment, Ginger, Coriander, Coffee, Hemp, Peppermint oil from any species of the Peppermint genus, Eucalyptus, Star anise, Cocoa, Lemongrass, Rooibos, Flax, Ginkgo, Hazelnut, Hibiscus, Bay laurel, Mate tea, Orange peel, Rose, Tea such as green or black tea, Thyme, Juniper, Elderflower, Basil, Bay leaf, Fennel, Oregano, Red paprika, Rosemary, Saffron, Lemon peel, Peppermint, Perilla, Turmeric, Coriander leaf, Myrtle, Blackcurrant, Valerian. The following ingredients are permitted: peppercorns, dried nutmeg bark, damien, marjoram, olives, lemongrass, lemon basil, chives, caraway, verbena, tansy, limonene, thymol, camphene; flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants; sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol); and other additives such as charcoal, chlorophyll, minerals, herbal ingredients, or breath fresheners. They may be imitations, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, such as liquids like oils, solids like powders, or gases.

[0109] In some embodiments, the flavoring agent includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent includes flavoring components of cucumber, blueberry, citrus fruits, and / or cranberry. In some embodiments, the flavoring agent includes eugenol. In some embodiments, the flavoring agent includes flavoring components extracted from tobacco.

[0110] In some embodiments, the flavoring agent may include a sensory agent intended to achieve a certain somatosensory sensation, which may be in addition to or replace aroma or taste nerves, typically induced and perceived chemically by stimulating the fifth cranial nerve (trigeminal nerve), and such sensory agents may include agents that provide heating, cooling, tingling, or numbing effects. Suitable heat-effecting agents may be, but are not limited to, vanillyl ethyl ether, and suitable coolants may be, but are not limited to, eucalyptol and WS-3.

[0111] Aerosolizable materials, also referred to herein as aerosol-generating materials, are materials capable of generating aerosols, for example, when heated, irradiated, or otherwise energized. Aerosolizable materials may be in the form of, for example, solids, liquids, or gels, and may or may not contain nicotine and / or flavorings.

[0112] Aerosol-generating materials (sometimes referred to herein as aerosolizable materials) are materials capable of generating aerosols, for example, when heated, irradiated, or otherwise energized. Aerosol-generating materials may be in the form of solids, liquids, or semi-solids (such as gels), and may or may not contain active substances and / or flavorings.

[0113] Aerosol generating materials may include one or more active substances and / or flavoring agents, one or more aerosol forming agent materials, and optionally one or more other functional materials.

[0114] Aerosol-generating materials may include binders such as gelling agents and aerosol-forming agents. Optionally, a substance to be delivered and / or a filler may also be present. Optionally, a solvent such as water may be present, and one or more other components of the aerosol-generating material may be soluble or insoluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant-based materials. Specifically, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0115] Aerosol generating materials may include or be in the form of aerosol generating membranes. Aerosol generating membranes may include binders such as gelling agents and aerosol forming agents. Optionally, a substance to be delivered and / or a filler may also be present. Aerosol generating membranes may be substantially free of plant material. Specifically, in some embodiments, the aerosol generating material is substantially free of tobacco.

[0116] The aerosol generating membrane can have a thickness of about 0.015 mm to about 1 mm. For example, the thickness can be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

[0117] The aerosol-generating membrane can be continuous. For example, the membrane may include or may be a continuous sheet of material.

[0118] Aerosol generating membranes can be discontinuous. For example, an aerosol generating membrane may include one or more discrete portions or regions of aerosol generating material, such as dots, strips, or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

[0119] Aerosol-generating membranes can be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol forming agent, and one or more other components, such as one or more substances to be delivered, to form a slurry, and then heating the slurry to evaporate at least some of the solvent to form an aerosol-generating membrane.

[0120] The slurry can be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent.

[0121] The aerosol generating material may be an "amorphous solid." In some embodiments, the amorphous solid is a "monomer-type solid." The aerosol generating material may be non-fibrous or fibrous. In some embodiments, the aerosol generating material may be a dry gel. The aerosol generating material may be a solid material that may retain some fluid, such as a liquid, within it. In some embodiments, the retained fluid may be water (such as water absorbed from the environment surrounding the aerosol generating material) or the retained fluid may be a solvent (such as when the aerosol generating material is formed from a slurry). In some embodiments, the solvent may be water.

[0122] Aerosol generating materials may include one or more active substances and / or flavoring agents, one or more aerosol forming agent materials, and optionally one or more other functional materials.

[0123] Aerosol forming agent materials may include one or more components capable of forming aerosols. In some embodiments, aerosol forming agent materials may include one or more of the following: glycerol, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl caprylate, triethyl citrate, glyceryl triacetate, a mixture of glyceryl diacetate, benzyl benzoate, benzyl phenylacetate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0124] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers and / or antioxidants.

[0125] The material may be present on or within the support to form a matrix. The support may be, for example, paper, cardboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a receptor. In some embodiments, the receptor is embedded within the material. In some alternative embodiments, the receptor is located on one or both sides of the material.

[0126] Consumables are articles comprising or composed of aerosol-generating materials, which are intended, in whole or in part, to be consumed by the user during use. Consumables may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery assembly, an aerosol-generating area, a housing, a covering, a nozzle, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to generate an aerosol. The heater may, for example, include a flammable material, a material that can be heated by electrical conduction, or a sensor.

[0127] The aerosol supply device may contain an article comprising aerosol-generating material for heating. In this context, "article" refers to an assembly that includes or contains aerosol-generating material and optionally includes or contains other components during use, and is heated to cause the aerosol-generating material to volatilize. A user may insert the article into or onto the aerosol supply device, and then heat the article to generate an aerosol, which the user subsequently inhales.

[0128] An aerosol generator is an apparatus configured to generate aerosols from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol generating material to thermal energy to release one or more volatiles from the aerosol generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate aerosols from the aerosol generating material without heating. For example, the aerosol generator may be configured to subject the aerosol generating material to one or more of vibration, pressure, or electrostatic energy.

[0129] Figure 1 This is a block diagram of an aerosol generating apparatus according to an exemplary embodiment, the aerosol generating apparatus being indicated by reference numeral 10 throughout.

[0130] The aerosol generating device 10 includes a battery 11 (e.g., a rechargeable battery), a control circuit 12, and an aerosol generator 13. As discussed in detail below, the aerosol generator 13 includes a resistance heater for heating an aerosolizable material (e.g., a membrane or gel) to generate an aerosol (e.g., vapor). The aerosolizable material is sometimes referred to as an aerosol generating material.

[0131] The aerosol generating apparatus 10 forms an aerosol supply system including an aerosol supply device and an article including an aerosol generator 13. The resistance heater includes at least one resistance heating element.

[0132] Battery 11 acts as a power source. The control circuitry acts as a controller and includes a processor and memory. The control circuitry is configured to implement the method or each of the methods described below.

[0133] During the use of device 10, air is drawn into the air inlet of aerosol generator 13, as indicated by arrow 16. The aerosol generated by aerosol generator 13 leaves the device at the air outlet, as indicated by arrow 17 (e.g., into the mouth of the user of device 10).

[0134] In some exemplary embodiments, the aerosol generating device 10 includes two main components: a control section 2 (which may be referred to as a reusable component) and a consumable component 4 (which may be referred to as a replaceable or disposable cartridge). During use of the aerosol generating device 10, the control section 2 and the consumable component 4 can be releasably connected at an interface 6. The consumable component 4 may be removable and replaceable (e.g., when the consumable component is depleted), wherein the control section 2 is reused along with different consumable components.

[0135] The aerosol generating device 10, also known as an aerosol supply system, includes: a control section 2, which may also be referred to as an aerosol supply device 10; and a consumable component 4, which may also be referred to as an article 4.

[0136] The aerosol generator 13 forms part of the article 4. The aerosol generator 13 includes a resistance heating configuration configured to heat at least one of an aerosol generating material, such as a membrane or a gel, to generate an aerosol.

[0137] In embodiments, the heating element, or each heating element, is a resistance heating element, as described in detail below. In such a configuration, the system includes a resistance heating generator comprising components for heating the heating configuration via a resistance heating process. In this case, current is applied directly to the resistance heating element, and the resulting current flow in the heating element, which acts as the heating component, causes the heating element to be heated by Joule heating. The resistance heating element includes a resistive material configured to generate heat when a suitable current passes through it, and the heating configuration includes electrical contacts for supplying current to the resistive material. Supplying a resistance heating configuration enables a compact configuration. Resistance heating provides an efficient construction.

[0138] A "section" can be called a "component". A "component" can be called a "section". Consumable components can be called replaceable or disposable items.

[0139] Of course, the aerosol generating device 10 is provided by way of example only and is highly illustrative. Many alternative aerosol generating devices and other devices can be used in exemplary implementations of the principles described herein. For example, in some exemplary embodiments, air is drawn into an air inlet in the control section 2, passes through interface 6, and exits the consumable component 4.

[0140] Aerosol generator 13 is configured to generate aerosols from an aerosol-generating material (also referred to as an aerosolizable material) when the aerosol supply system is operated, as will be described in detail below. The aerosol supply system 10 is elongated and extends along a longitudinal axis. The aerosol supply system 10 has a proximal end that is closest to the user (e.g., the user's mouth) when the user inhales the aerosol generated by the aerosol supply system, and a distal end that is furthest from the user during use. The proximal end may also be referred to as the "mouth end." The aerosol supply system is accordingly defined in a proximal direction that directs the user during use. Similarly, the aerosol supply system 10 is defined in a distal direction that directs the user away from the user during use. The terms "proximal" and "distal" used to describe features of system 10 will be described with reference to the relative positioning of these features in the proximal-distal direction along the longitudinal axis.

[0141] In an embodiment, the aerosol generator 13 may be fully or partially inserted into the aerosol supply device 10. The configuration of the aerosol supply device 10 may vary; for example, the opening may be located in the longitudinal sidewall of the aerosol supply device 10, and / or may be closed during use by another feature of the aerosol supply device 10. In this configuration, the article 4 defines the mouthpiece at its proximal end. In an embodiment, the aerosol supply device 10 defines the mouthpiece. The user places their mouth over the mouthpiece during use.

[0142] Figure 2 This is a block diagram of an aerosol generator according to an exemplary embodiment, which is indicated generally by reference numeral 20. Aerosol generator 20 is an exemplary embodiment of aerosol generator 13 of the aerosol generating apparatus 10 described above.

[0143] The aerosol generator 20 includes an aerosolizable layer 22 (bonded with an aerosolizable material) and a conductive layer 24 in contact with the aerosolizable layer. As described in detail below, the conductive layer 24 is formed as one or more heating elements, each providing a conductive path for resistive heating of a portion of the aerosolizable material in the aerosolizable layer 22 to generate an aerosol. The aerosolizable material may be, for example, in the form of a film or a gel.

[0144] The aerosolizable layer 22, also known as the aerosol generating layer 22, includes an aerosolizable material, also known as an aerosol generating material.

[0145] The conductive layer 24 is formed as a resistance heating layer. The resistance heating layer includes a material that is resistively heated in response to an electric current passing through it.

[0146] The aerosol generator 20 includes a resistance heating layer 24. An aerosol generating layer 22 is located on the resistance heating layer 24. The aerosol generating layer 22 is in direct contact with the resistance heating layer 24. In an embodiment, the aerosol generating layer 22 is in indirect contact with the resistance heating layer 24. In an embodiment, the resistance heating layer 24 may include a coating. The coating of the resistance heating layer 24 may be located on a conductive material.

[0147] The conductive layer 24 may be in the form of a metallic layer such as an aluminum layer or a non-metallic material such as graphene. The conductive layer may be in the form of a foil (e.g., aluminum foil).

[0148] The aerosol generator 20 is configured to generate aerosols from the aerosol generating material when the aerosol supply system 10 is operated, as will be described in detail below.

[0149] Figure 3This is a block diagram of an aerosol generator according to an exemplary embodiment, which is indicated generally by reference numeral 30. Aerosol generator 30 is an exemplary embodiment of the aerosol generator 13 described above.

[0150] The aerosol generator 30 includes the aerosolizable layer 22 and conductive layer 24 described above. The aerosol generator 30 further includes a support (or substrate) 32. The support 32 may include paper or card material providing structural support for the aerosol generator 30. Figure 3 As shown, in the aerosol generator 30, the conductive layer 24 is sandwiched between the support member 32 and the aerosolizable layer 22.

[0151] In the embodiments described herein, the support member 32 may be configured as a support layer. The support member 32 may be electrically insulating. The support member 32 may include at least one of paper and card. In embodiments, the aerosolizable layer 22 is in direct contact with the conductive layer 24. The aerosolizable layer 22 may be in indirect contact with the conductive layer 24. The conductive layer 24 and the support layer define a substrate. The substrate 32 supports the aerosol generating layer 22. The support layer includes a card layer. The support member 32 is non-perforated.

[0152] In one embodiment, the aerosol generator 30 may include a laminate comprising a conductive layer 24 and a support layer 32. In another embodiment, the laminate includes an aerosolizable layer 22. The aerosolizable layer 22 may be formed as a continuous structure or may be formed from discrete portions. The discrete portions may include one or more of dots, strips, spirals, or other shapes. In another embodiment, the discrete portions are aligned with a heating element.

[0153] One or more of the aerosolizable layer 22, the conductive layer 24, and the support layer 32 may include an additional layer. For example, the support layer 32 may include a backing layer or an intermediate layer. In this embodiment, the support layer 32 is omitted.

[0154] The aerosol generator, or each aerosol generator 30, is formed in a stacked configuration. Other configurations of the article, such as tubular configurations, are also contemplated in the embodiments. In such tubular configurations, the aerosol generator 30 defines the tubular structure. The tubular shape may include a circular cross-section and other polygonal shapes.

[0155] In one embodiment, as shown in the figure, article 30 has a flat structure. That is, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to both the length and the width, wherein the length is greater than or equal to the width, and wherein the width is greater than the depth. Other structures are also conceivable.

[0156] Figure 4A conductive layer, indicated generally by reference numeral 40, is shown according to an exemplary embodiment. The conductive layer 40 includes a heating element 42, a first electrical connection 44, and a second electrical connection 46. In some exemplary embodiments, the first electrical connection 44 provides a positive connection and the second electrical connection 46 provides a negative connection, such that current flows through the heating element 42 between these electrical connections. Figure 4 As shown, the heating element 42 includes multiple perforations (including perforations 43a, 43b, 43c, etc.).

[0157] Multiple perforations serve as surface features. In embodiments, surface features include at least one of protrusions, grooves, indentations, recesses, holes, perforations, gaps, etc. Surface features may be localized deformations or formations of a layer such that at least one of the material volumes across the thickness and / or width of the heating element at one or more specific locations along the heating element differs from the material volumes across the thickness and / or width of the heating element at other one or more specific locations along the heating element. The embodiments described herein depict multiple perforations for illustrative purposes, and those skilled in the art will understand that multiple protrusions may be any surface feature.

[0158] The resistance of the heating element 42 can depend on the nature of the perforations in the conductive layer (e.g., the size, number, and distribution of the perforations). Therefore, a perforated conductive layer can have a higher resistance compared to a straight, perforation-free path between the first and second electrical connectors.

[0159] The conductive layer 40 can be used as the conductive layer 24 of the aerosol generator 20 or 30 (or a similar aerosol generator), such that the conductive path of the heating element 42 can be used to resistively heat a portion of the aerosolizable material to generate an aerosol.

[0160] Figure 5 A conductive layer, generally indicated by reference numeral 50, is shown according to an exemplary embodiment. The conductive layer 50 includes a first heating element 52a, a second heating element 52b, first electrical connections 54a and 54b, and a second electrical connection 56. In some exemplary embodiments, the first electrical connections 54a and 54b are each provided with a positive connection and the second electrical connection 56 is provided with a negative connection, such that current flows through the heating elements 52a and 52b between these electrical connections.

[0161] The number of electrical connections (also referred to as electrical contacts) can vary. Thus, each heating element 52a, 52b extends between discrete first-type electrical contacts 54a, 54b and a common second-type electrical contact 56.

[0162] like Figure 5As shown, heating elements 52a and 52b include multiple perforations (including perforations 53a, 53b, 53c, etc.). The two heating elements are formed by a cut 58 in the conductive layer, which separates the first heating element from the second heating element. The cut 58 can be produced by laser cutting or a similar process (discussed further below).

[0163] Perforations are located in the conductive layer 40. In an embodiment, at least some of the plurality of perforations are formed along a conductive path. The plurality of perforations may affect the electrical characteristics of the conductive path. In an embodiment, the plurality of surface features are configured to at least partially determine the resistance along the conductive path. In an embodiment, the plurality of surface features are configured not to affect the resistance along the conductive path or to minimize the effect.

[0164] Perforations can be arranged in a variety of configurations within a heating element. The heating element may include an array of perforations. The heating element may include multiple arrays of perforations. The perforations may be regularly spaced apart within the perforation array. In various embodiments, multiple distributions of the perforations are contemplated. The perforations may be distributed in any of the following ways: parallel columns, parallel rows, regularly, irregularly, randomly, etc.

[0165] In an embodiment, the aerosolizable layer 22 may include a plurality of aerosol-generating layer perforations. The plurality of perforations in the conductive layer are aligned with the plurality of aerosol-generating layer perforations. This can be advantageous because it further enables gas flow, as will be described below. Furthermore, quality control of the fabrication of the conductive layer and the aerosolizable layer can be more easily monitored. It can also further reduce the effects of delamination, as will be further described below. In an embodiment, various distributions of the perforations are contemplated, including any of the following: parallel columns, parallel rows, regular, irregular, random, etc. The aerosol-generating layer may also be without perforations.

[0166] In one embodiment, the conductive layer 24 includes a plurality of support through-holes. The support through-holes are configured to correspond to surface features of the support member. The plurality of surface features of the conductive layer are aligned with the plurality of support through-holes. The support through-holes of the conductive layer 24 help position the conductive layer onto the support member. In another embodiment, the aerosolizable layer 22 is physically bonded to the support member 32. The conductive layer is sandwiched between the support member 32 and the aerosolizable layer 22.

[0167] The conductive layer 50 can be used as the conductive layer 24 of the aerosol generator 20 or 30 (or a similar aerosol generator), allowing the conductive paths of the heating elements 52a and 52b to be used for resistive heating of a portion of the aerosolizable material to generate an aerosol. Furthermore, by providing separate first electrical connections 54a and 54b, the heating elements 52a and 52b can be independently controlled to control the generation of aerosols from different portions of the aerosolizable material.

[0168] In one embodiment, the aerosol generation layer 22 is a continuous aerosol generation layer. In another embodiment, the aerosol generation layer 22 is a discontinuous aerosol generation layer. In yet another embodiment, the aerosol generation layer includes a plurality of discrete aerosol generation portions. Each of the heating elements can heat a corresponding discrete portion of the aerosolizable layer. Advantageously, each discrete portion can be configured to provide a different experience to the user during aerosol generation.

[0169] Figure 6 A heating element according to an exemplary embodiment is shown, the heating element being indicated generally by reference numeral 60. One or more heating elements 60 may be formed from the conductive layer 24 described above.

[0170] The heating element 60 includes a non-straight conductive path between a first electrical connection 62 and a second electrical connector 63. In some exemplary embodiments, the first electrical connection 62 provides a positive connection and the second electrical connection 63 provides a negative connection, such that current flows through the path between these electrical connections. The tortuous nature of the path of the heating element 60 increases the total length of the path between the first and second electrical connectors, thereby increasing the resistance of that path (compared to a straight, direct path between the first and second electrical connectors).

[0171] In one embodiment, the conductive layer 24 includes a first type of electrical track 64 extending from the heating element 62. The first type of electrical track 64 includes a first type of electrical connection portion 62. The first type of electrical contact 62 is configured for electrical connection with a device electrical connector. The first type of electrical contact 62 includes a first type of exposed contact area. The first type of exposed contact area is exposed on the article of manufacture for direct connection with the device electrical connector.

[0172] In one embodiment, the conductive layer 24 includes a second type of electrical track 65 extending from the heating element 60. The second type of electrical track 65 includes a second type of electrical connection 63. The second type of electrical connection 63 is configured for electrical connection with a device electrical connector. The second type of electrical contact 63 includes a second type of exposed contact area. The second type of exposed contact area is exposed on the article of manufacture for direct connection with the device electrical connector.

[0173] As discussed in detail below, the conductive path of the heating element 60 can be established by forming tracks within the heating element, for example, by cutting tracks in the conductive layer constituting the heating element. In some exemplary embodiments, the tracks may have a width of approximately 0.5 mm to 1 mm (the two exemplary prototypes have widths of 0.93 mm and 0.72 mm, respectively) and a gap of less than approximately 0.25 mm between the tracks (the same two exemplary prototypes have gaps of 0.2 mm and 0.05 mm, respectively). The heating element may have an overall size of approximately 10 mm × 10 mm. Of course, other sizes are possible in other exemplary embodiments. By forming heating elements of these sizes from aluminum foil with a thickness of 0.006 mm and a resistivity between 2 µOhmcm and 6 µOhmcm, the resistance of the path has been calculated to be approximately 1 ohm. In one exemplary embodiment, the resistance was measured to be between 0.83 ohms and 1.31 ohms.

[0174] The resistance heating layer includes multiple resistance heating elements 40. The multiple heating elements 40 are formed in an array, according to... Figure 5 As shown in the diagram. The array of heating elements can be arranged in a single row. The array of heating elements can be arranged in a single row along the longitudinal axis of the aerosol generator. The array of heating elements can be arranged in a single row transversely to the longitudinal axis of the aerosol generator. Other configurations are also conceivable.

[0175] The resistance heating layer 24 includes a first type of electrical track 44 extending from the resistance heating element 40. The first type of electrical track 44 includes a first type of electrical contact 42. The first type of electrical contact 42 is configured for electrical connection with a device electrical connector. The first type of electrical contact 42 includes a first type of exposed contact area. The first type of exposed contact area is exposed on the article of manufacture for direct connection with the device electrical connector.

[0176] The resistance heating layer 24 includes a second type of electrical track 45 extending from the resistance heating element 40. The second type of electrical track 45 includes a second type of electrical contact 43. The second type of electrical contact 43 is configured for electrical connection with a device electrical connector. The second type of electrical contact 43 includes a second type of exposed contact area. The second type of exposed contact area is exposed on the article for direct connection with the device electrical connector.

[0177] In one embodiment, the conductive path of the heating element is established by defining at least one electrically insulating barrier in the resistive heating layer 24. In another embodiment, the electrically insulating barrier is formed by cutting conductive limiting elements (i.e., electrically insulating portions) such as gaps, channels, or slots in a sheet formed of conductive material to form the resistive heating layer 24. In another embodiment, the resistive heating layer 24 is pre-formed to define the resistive heating element or each resistive heating element 40 and then applied to the support 32. In yet another embodiment, the resistive heating layer 24 is applied to the support 32, and the resistive heating element or each resistive heating element 40 is then defined within the resistive heating layer 24. The resistive heating element or each resistive heating element 40 defining the resistive heating layer 24 may be a printed heater. At least one electrically insulating barrier defines first-type and second-type electrical tracks. The electrically insulating barrier is an electrically conductive defining barrier that passes through the barrier.

[0178] The insulating barrier may be an air gap. In an embodiment, the insulating barrier is a filled gap, for example, filled with an insulating material. The barrier is an electrically conductive demarcation barrier that passes through it.

[0179] The resistive heating element or each resistive heating element 60 defining the resistive heating layer 24 can be formed by a cutting action. Cutting may include die-cutting. The resistive heating element can be formed by an action applied only to the resistive heating layer. In an embodiment, the resistive heating element can be formed by an action applied to both the resistive heating layer and the support layer, such as cutting the resistive heating layer and the support layer.

[0180] Figure 7 A conductive layer according to an exemplary embodiment is shown, the conductive layer being generally indicated by reference numeral 70. The conductive layer 70 includes a heating element 72, a first electrical connection 74 (e.g., a positive connection structure), and a second electrical connection 76 (e.g., a negative connection structure). Figure 6 As shown, the heating element 72 includes multiple perforations (including perforations 73a, 73b, 73c, etc.).

[0181] Heating element 72 includes a non-straight conductive path (formed by cuts, including cuts 78a and 78b and other similar cuts in the conductive layer separating the first and second heating elements) between the first electrical connection 74 and the second electrical connection 76. Similar to heating element 60 described above, the tortuous nature of the path in heating element 72 increases the total length of the path between the first and second electrical connectors, thus increasing the resistance of that path (compared to a straight, direct path between the first and second electrical connectors). This is supplemented by the increased resistance due to the multiple perforations. Therefore, the resistance of heating element 72 can depend on the length of the conductive path and the nature of the perforations in the conductive layer (e.g., the size, number, and distribution of the perforations).

[0182] In this embodiment, the resistance of each heating element 72 among the plurality of heating elements may vary. Each heating element among the plurality of heating elements may have the same resistance. At least one resistive heating element among the plurality of heating elements may have a different resistance than another resistive heating element. The resistance of the electrical connections among the heating elements may vary. The resistance of each heating element may vary depending on the resistance of its associated electrical connection, such that the total resistance of the electrical connection and the heating element is the same for all portions of the conductive layer 24.

[0183] In embodiments, each heating element has the same plurality of perforations. At least one resistive heating element may have a plurality of perforations different from those of another heating element. Multiple surface features of at least one heating element have at least one of the sizes, numbers, and distributions of perforations different from those of another heating element. The resistance of the heating element can be adjusted, configured, or tuned according to the requirements of the heating element. Advantageously, heating elements with different resistances can provide different heating characteristics, which can provide different experiences for the user. In one example, the heating element may be configured as part of a respective heating material, which is a component different from one or more of the other parts. The heating elements may be configured to each have a different temperature profile.

[0184] The conductive layer 70 can be used as the conductive layer 24 of the aerosol generator 20 or 30 (or a similar aerosol generator), so that the conductive path of the heating element 72 can be used for resistive heating of aerosolizable materials to generate aerosols.

[0185] Figure 8 A conductive layer according to an exemplary embodiment is shown, which is indicated generally by reference numeral 80. The conductive layer 80 is an exemplary embodiment of the heating element 24 of the aerosol generator 20 or 30 described above.

[0186] The conductive layer 80 is formed as a plurality of heating elements, which are generally indicated by reference numerals 81 to 85. Each of the heating elements 81 to 85 includes a non-linear path extending from a first type of electrical connection (connection structures 86a to 86e, respectively) to a second type of electrical connection (connection structure 88). Therefore, the conductive layer 80 provides a plurality of heating elements similar to the heating elements 60 and 72 described above. It should be noted that the conductive layer 80 may include perforations (not shown) in a manner similar to the conductive layer 70 described above.

[0187] When layer 80 is used as heating element 24 of aerosol generator 20 or 30, each of heating elements 81 to 85 provides a conductive path for resistive heating of a portion of aerosolizable material 22 to generate aerosol at the corresponding portion of the support.

[0188] The separate electrical connections 86a to 86e of the first type allow current to be independently supplied to each of the plurality of heating elements 81 to 85. Therefore, heating of different zones of the aerosolizable material can be controlled. For example, the aerosol generator may have five aerosol generation zones. Layer 80 allows each of these zones to be activated separately. Thus, for example, five puffs of aerosol can be generated from a single consumable incorporating heating elements 81 to 85.

[0189] Therefore, for example, five aerosols can be generated from a single consumable with a single aerosol generator 20 or 30, and ten aerosols can be generated from a single consumable with two aerosol generators 20 or 30.

[0190] In the exemplary conductive layer 80, a plurality of first-type electrical connections 86a to 86e (e.g., positive electrical connections) are provided, and a single second-type connection structure 88 (e.g., negative electrical connection) is provided. This is not necessary for all embodiments. For example, a plurality of second-type connection structures may be provided.

[0191] In an embodiment, each resistive heating element 81 to 85 includes a corresponding one of the first type of electrical contacts 86a to 86e and a corresponding one of the second type of electrical contacts 88.

[0192] In the exemplary conductive layer 80, a first type of electrical connection is disposed on a first edge of the conductive layer, and a second type of electrical connection is disposed on a second edge of the conductive layer. This allows for convenient electrical connection, but of course, many other configurations are possible, some of which are discussed further below.

[0193] Figure 9 A conductive layer according to an exemplary embodiment is shown, which is indicated generally by reference numeral 90. The conductive layer 90 is an exemplary embodiment of the heating element 24 of the aerosol generator 20 or 30 described above.

[0194] The conductive layer 90 includes a heating element 92, a first electrical connection 94 of a first type, a second electrical connection 95 of a first type, a first electrical connection 96 of a second type, and a second electrical connection 97 of a second type. In some exemplary embodiments, the first type of electrical connection provides a positive electrical connection, and the second type of electrical connection provides a negative electrical connection.

[0195] Heating element 92 has a higher resistance than electrical connections 94 to 97. This is at least in part due to the perforation in heating element 92. Figure 9 This was caused by (as shown in the video).

[0196] In use, current can flow from electrical connection 94 to electrical connection 96 via conductive layer 92. Similarly, current can flow from electrical connection 95 to electrical connection 97 via conductive layer 92. The higher resistivity of heating element 92 (compared to the electrical connections) tends to limit the flow of current between electrical connections 94 and 97, and between electrical connections 95 and 96. Therefore, conductive layer 90 can be divided into different zones, which can be heated separately (to a certain extent).

[0197] Figure 10 A flowchart illustrating the processing logic according to an exemplary embodiment is provided, the processing logic being indicated in general by reference numeral 100.

[0198] Processing logic 100 begins with operation 102, in which a conductive layer is formed into one or more heating elements (e.g., multiple heating elements), wherein each heating element extends from a first type of electrical connection to a second type of electrical connection.

[0199] In other words, each heating element is at least a portion of a corresponding conductive path between a first-type electrical connection and a second-type electrical connection. This conductive layer can be considered a blank. The blank can be used to form an aerosol generator.

[0200] In the presence of a support, the heating element or individual heating elements may be formed before or after the conductive layer is applied to the support. The conductive layer may be adhered to the support, or mounted or formed on the support in different configurations.

[0201] In use, the heating element or heating elements may be used to provide a conductive path for resistive heating of a portion of an aerosolizable material to generate an aerosol. The conductive layer may be perforated; alternatively, a perforation process may be provided (discussed further below).

[0202] At operation 104, for example, an aerosolizable layer comprising an aerosolizable material is added by placing the formed conductive layer in contact with the aerosolizable layer.

[0203] In other words, at operation 104, at least one of the formed resistance heating layer and aerosol generating layer is placed in contact with another component, wherein the aerosol generating layer is incorporating an aerosol generating material. Alternatively, the aerosol generating layer is formed on the resistance heating layer.

[0204] In optional operation 106, the combination of the heating element and the aerosolizable layer can be positioned to contact the support.

[0205] Therefore, processing logic 100 can be used to generate the aerosol generator 20 or 30 described above (e.g., in combination with one of the conductive layers 40, 50, 70, 80 or 90 described above).

[0206] Figure 11 A flowchart illustrating the processing logic for forming an aerosol generator according to an exemplary embodiment is provided, the processing logic being indicated generally by reference numeral 110. In processing logic 110, the conductive layer is perforated before the heating element is placed in contact with the aerosolizable layer.

[0207] Processing logic 110 begins with operation 112, in which a perforated conductive layer is obtained. Operation 112 can be implemented by obtaining a perforated conductive material or by perforating the conductive material as an initial step (i.e., including the perforation action).

[0208] In operation 114, for example, the perforated conductive layer is combined with the aerosolizable layer by placing the formed (and perforated) conductive layer in contact with the aerosolizable layer, wherein the aerosolizable layer is incorporating an aerosolizable material (e.g., in gel form), as discussed above.

[0209] In optional operation 116, the combination of the perforated heating element and the aerosolizable layer can be positioned to contact the support.

[0210] Figure 12 A flowchart illustrating the processing logic according to an exemplary embodiment is provided, the processing logic being indicated in general by reference numeral 120.

[0211] Processing logic 120 begins with operation 122, in which the conductive layer is combined with the aerosolizable layer, for example, by placing the formed conductive layer in contact with the aerosolizable layer, wherein the aerosolizable layer is incorporating an aerosolizable material, as discussed above.

[0212] At operation 124, a perforation is formed in the conductive layer of the heating element. Operation 124 may include forming a perforation in the aerosolizable layer.

[0213] In optional operation 126, the combination of the heating element and the aerosolizable layer can be positioned to contact the support.

[0214] Figure 13 A flowchart illustrating the processing logic according to an exemplary embodiment is provided, the processing logic being indicated in general by reference numeral 130.

[0215] Processing logic 130 begins with operation 132, in which the conductive layer is combined with the aerosolizable layer, for example, by placing the formed conductive layer in contact with the aerosolizable layer, wherein the aerosolizable layer is incorporating an aerosolizable material, as discussed above. Therefore, operation 132 is the same as operation 122 described above.

[0216] At operation 134, the combination of the heating element and the aerosolizable layer is placed in contact with the support.

[0217] At operation 136, a perforation is formed in the conductive layer of the heating element. Operation 124 may include forming a perforation in an aerosolizable material and / or a support.

[0218] In the examples of providing perforations in both the conductive layer and the aerosolizable layer in the processing logics 100 to 130 described above, such perforations in the two layers can be similar. However, this is not necessary for all exemplary embodiments. As discussed above, perforations can be provided in the conductive layer to adjust the resistance of the layer. In contrast, perforations can be provided in the aerosolizable layer to allow gas to escape from the layer (acting as vents). In some exemplary embodiments, perforations in the aerosolizable layer can help reduce delamination of the aerosol generator layer. Identical perforations in both layers are not necessary for all exemplary embodiments. For example, the number and pattern of perforations can differ. Thus, for example, in processing logics 120 and 130, the perforated conductive layer and the unperforated aerosolizable layer can be formed together in operation 122 or 132, and additional perforations can be provided in both layers in operation 124 or 136. Similarly, in processing logic 110, layers perforated in different ways can be obtained (e.g., in operation 112).

[0219] In addition to altering the resistance of the conductive layer, providing perforations in an aerosol generator, which includes an aerosolizable layer and a support, also allows the aerosolizable material (e.g., a gel) to physically bond with the support (if provided) through the perforations in the conductive layer. This facilitates physical bonding of the layers and reduces the risk of delamination in the aerosol generator layers. In fact, in some exemplary embodiments, the perforations in the aerosolizable layer can be omitted due to the reduced risk of delamination.

[0220] Figure 14 An aerosol generator formed according to an exemplary embodiment is shown, the aerosol generator being indicated generally by reference numeral 140. The aerosol generator 140 includes a conductive layer 142 and an aerosolizable layer 144 incorporating an aerosolizable material. The aerosolizable material may be formed on layer 144, for example, by deposition, such as by spraying, brushing, application, or some other method.

[0221] In an exemplary embodiment of operation 102 of the processing logic 100 described above, the conductive layer 142 is formed as one or more heating elements. The conductive layer 142 may be, for example, one of the conductive layers 40, 50, 60, 70, 80 or 90 described above.

[0222] In exemplary embodiments of operations 104, 114, 122, or 132 of the processing logic described above, the conductive layer 142 and the aerosolizable layer 144 are positioned in contact with each other (as indicated by arrow 146). The conductive layer 142 may include perforations, which may be formed in the layer 142 before or after it is positioned in contact with the support 144 (as discussed above). The aerosolizable layer 144 may or may not have perforations, as discussed above.

[0223] Figure 15 A conductive layer 150 formed according to an exemplary embodiment is shown. A laser cutter 152 is used to cut the conductive layer 150. The cutting of the conductive layer 150 can be used to form paths for the heating element described herein. The conductive layer 150 may include the perforations discussed above (not shown).

[0224] The use of a laser cutter 152 (or some other cutting process) is not the only way to produce the conductive layer described herein. Some exemplary methods are described below.

[0225] Figure 16 A flowchart illustrating the processing logic according to an exemplary embodiment is provided, the processing logic being indicated in general by reference numeral 160.

[0226] Processing logic 160 begins with operation 162, in which a conductive layer is provided. At operation 164, one or more heating elements are formed in the conductive layer by chemical etching. Operations 162 and 164 are exemplary embodiments of operation 102 of processing logic 100 described above. The conductive layer is then placed in contact with the aerosolizable layer by performing operation 104 described above.

[0227] Figure 16 The flowchart may also be referred to as a portion illustrating the method or processing logic for forming aerosol generators 20, 30, and 70. In an embodiment, method or processing logic 160 begins at operation 162, in which a resistive heating layer is provided. At operation 164, one or more resistive heating elements are formed in the resistive heating layer by chemical etching. Operations 162 and 164 are exemplary embodiments of operation 62 of method 60 described above. Aerosol generating material is then placed on the resistive heating layer by performing operation 104 described above.

[0228] Figure 17 A flowchart illustrating the processing logic according to an exemplary embodiment is provided, the processing logic being indicated in general by reference numeral 170.

[0229] Processing logic 170 begins with operation 172, in which a heating element is formed, at least partially, by printing a conductive layer. Therefore, operation 172 is an exemplary embodiment of operation 102 of the processing logic 100 described above. The conductive layer is then placed in contact with the aerosolizable layer, by implementing operation 104 as described above.

[0230] Figure 17 The flowchart may also be referred to as a portion illustrating the method or processing logic (indicated generally by reference numeral 170) for forming aerosol generators 20, 30, and 70. The method or processing logic 170 begins with operation 172, in which one or more heating elements are formed, at least partially, by printing a resistance heating layer. Therefore, operation 172 is an exemplary embodiment of operation 162 of the processing logic 160 described above. Aerosol-generating material is then placed on the resistance heating layer, thereby implementing operation 104 described above.

[0231] The cutting, etching, and printing methods described above are provided with examples; alternative methods are also possible. For instance, a so-called "hot foiling" method can be used, in which the heating element is made of a conductive layer and then assembled / bonded to the substrate. Other techniques can be used, such as die-cutting or punching (e.g., perforation) in the conductive layer. Furthermore, two or more techniques can be combined (e.g., by adding more conductive materials such as additional foil, printing material, etc., to increase the conductivity of the connection traces). Those skilled in the art will recognize many other techniques or combinations of techniques that can be used in implementations of the principles described herein.

[0232] Figure 18 A flowchart illustrating the processing logic according to an exemplary embodiment is provided, the processing logic being indicated generally by reference numeral 180. Processing logic 180 may be implemented, for example, using any of the aerosol generators described herein.

[0233] Processing logic 180 begins upon receiving a heating start command in the example of operation 182. In response to the heating start command, (in operation 184) it is determined whether heating elements are available. As discussed above, multiple heating elements can be provided by the conductive layer described herein. Operation 184 may involve determining which heating elements have been used (and correspondingly, which available aerosolizable material has been exhausted).

[0234] If a heating element is available, the processing logic moves to operation 186, in which the available heating element is used. As discussed above, the heating element can be controlled individually, for example, by supplying power to a separate heating element. Once operation 186 is complete, the processing logic terminates at operation 188.

[0235] If it is determined at operation 184 that all heating elements are unavailable (e.g., because all heating elements are already in use), the processing logic terminates at operation 188. This may mean that the consumable parts being used to implement processing logic 180 need to be replaced.

[0236] Figure 19 A conductive layer according to an exemplary embodiment is shown, the conductive layer being generally indicated by reference numeral 190. The conductive layer 190 may be formed using a laser cutter (similar to the laser cutter 152 described above) or some similar apparatus, but other methods (such as chemical etching or printing, as discussed above) may be used. The conductive layer 190 may include vias, as discussed above.

[0237] In other words, the resistance heating layer 190 can be formed using the laser cutting machine 152 described above or a similar device or another method. Each resistance heating element extends from one of the first type of electrical contacts (e.g., positive electrical contacts) to a second type of electrical contact (e.g., negative electrical contacts).

[0238] The conductive layer 190 includes a plurality of heating elements, each of which is a linear heating element and includes a conductive path extending across the length of the support. Each heating element extends from a first type of electrical connection (e.g., a positive electrical connection) to a second type of electrical connection (e.g., a negative electrical connection).

[0239] In the exemplary layer 190, both types of electrical connections are disposed at the same end of the layer and are positioned close to each other. Therefore, the exemplary path of layer 190 extends from one end of the layer to the other and then back again. It should be noted that there is no shared second connection structure as in some other exemplary embodiments; in fact, each heating element has individual first and second electrical connections.

[0240] Figure 20 A conductive layer according to an exemplary embodiment is shown, the conductive layer being generally indicated by reference numeral 200. The conductive layer 200 may be formed using a laser cutter (similar to the laser cutter 152 described above) or some similar apparatus, but other methods (such as chemical etching or printing, as discussed above) may be used. The conductive layer 200 may include vias, as discussed above.

[0241] The conductive layer 200 includes a plurality of heating elements, each of which is a linear heating element and includes a conductive path extending across the length of a support. Each heating element extends from a first type of electrical connection (e.g., a positive electrical connection) to a second type of electrical connection (e.g., a negative electrical connection). In the exemplary layer 200, the electrical connections of each type are located at opposite ends of the layer and provide a common second (negative) connection structure. Although a linear path (rather than a zigzag path) is provided, resistance is provided by providing a zigzag path. It should be noted that the path in any other embodiment described herein may also be zigzag.

[0242] Figure 21 A portion of an aerosol generator 210 according to an exemplary embodiment is shown. As discussed above, the aerosol generator 210 may include a conductive layer having a plurality of first-type electrical connections (e.g., providing positive electrical connections to each of a plurality of heating elements) and a single second-type electrical connection (e.g., providing a common negative electrical connection to the plurality of heating elements).

[0243] In other words, article 300 has an article electrical contact structure. In an embodiment, the electrical contact structure is formed by an aerosol generator 210. The electrical contact structure includes heater electrical contacts 212, 214. The heater electrical contacts may also be referred to as heaters or article contacts 212, 214. The aerosol supply device includes... Figure 22 The electrical connector 220 is shown in the image. The electrical connector includes connector electrical contacts. Connector electrical contacts may also be referred to as connector or device contacts. The article electrical contacts are configured to be in electrical communication with the device electrical connector 220.

[0244] The first type of electrical contact 62 and the second type of electrical contact 63, namely the heater contact, together form at least part of the product electrical contact structure of the aerosol generators 20, 30, and 70.

[0245] A resistance heating element 60 is located on the inner side of the resistance heating layer. This inner side defines a first side of the aerosol generator 210. Heater contacts 62 and 63 are located on a second side of the resistance heating layer. This second side defines an outer side of the aerosol generator 210. The heater contacts are exposed to allow them to contact the device's electrical connector. The heater contacts are located on the side of the resistance heating layer opposite the resistance heating element. Other configurations are conceivable.

[0246] The support layer 32 is located between the inner part of the resistance heating layer and the outer part of the resistance heating layer.

[0247] The construction of article 300 can vary. Article 300 includes a body 302. Body 302 may be hollow. Body 302 may define a flow path through article 300. The flow path extends between an air inlet and an aerosol outlet. The flow path is defined by an internal space within the article, along which air and / or aerosol can flow. The flow path is defined within body 302. The aerosol generator or individual aerosol generators 210 delineate the flow path. Aerosol generating material is exposed to the flow path. Aerosol generating material is exposed to the internal space. In an embodiment, the internal space includes two or more chambers.

[0248] exist Figure 21 The distal end of article 300 is shown in the image. As shown, body 302 includes multiple body layers. The body layers are arranged as stacked body layers 304. The body layers form a laminate. In an embodiment, the body layers are card layers. Other suitable materials may be used. Body layers 304 are configured to define features of article 300. In an embodiment, at least one body layer includes a gap defining an air inlet. The gap defines an opening 306.

[0249] The air inlet includes an opening 306. The opening is formed in the body 302. In an embodiment, the opening 306 is formed in another component of the article 300, such as the aerosol generator 210 or another wall feature. The aerosol outlet includes an outlet opening. The outlet opening is formed in the body 302. In an embodiment, the outlet opening is formed in another component of the article 300, such as the aerosol generator 210 or another wall feature.

[0250] In one embodiment, article 300 may include two aerosol generators 210 forming an aerosol generator configuration. The number of aerosol generators 210 may be different. Each aerosol generator 210 includes an aerosol generating material. The aerosol generating material is exposed to a flow path. In another embodiment, article 300 includes a single aerosol generator 210.

[0251] The aerosol generator 210 includes multiple external connectors, the construction of which depends on the construction of the first and second types of electrical connections of the aerosol generator. For example, Figure 21 The aerosol generator shown includes multiple external connectors (each connected to one of the first type of electrical connections) indicated by reference numeral 212 and another additional external connector 214 (connected to a second type of electrical connection). The aerosol generator 210 may have additional external connectors corresponding to connectors 212 and 214 on the lower side of the device (in... Figure 21 (Not visible in the middle).

[0252] Figure 22A connector 220 is shown for use in some exemplary embodiments. The connector has separate pins for connection with electrical contacts, such as connectors 212 and 214 described above.

[0253] Figure 23 This is a block diagram of an aerosol generating apparatus according to an exemplary embodiment, generally indicated by reference numeral 230. The system includes the aerosol generator 230 described above, a first connector 220a and a second connector 220b (similar to connector 220 described above), and a control section 232.

[0254] Control section 232 is similar to the reference above. Figure 1 The control section 2 of the described aerosol generating device 10. The aerosol generator 210 is similar to the consumable component 4 of the aerosol generating device 10. Connectors 220a and 220b allow the control section 232 to be inserted into the aerosol generator 210 (according to...). Figure 23 (As shown in the diagram) regulated or controlled voltages and / or currents are supplied to various electrical connections of the first and second type aerosol generators 210. For example, control section 232 may implement, for instance, the processing logic 180 described above.

[0255] In some embodiments of the aerosol generator and articles of manufacture described above, the aerosol generating material is formed with a structure other than an aerosol generating layer. In embodiments, the aerosol generating material is in the form of an aerosol generating segment. The aerosol generating segment typically comprises a solid material. This solid material may be shredded tobacco. For example, an aerosol generating material configured as an aerosol generating segment may comprise multiple individual aerosol generating material pieces. The aerosol generating material may be a single tobacco material piece. In embodiments, the aerosol generating material comprises multiple strips, beads, or granules. In embodiments, the aerosol generating segment is a plug.

[0256] In this embodiment, the aerosol generating segment includes a material body. The aerosol generating material is non-liquid. In this embodiment, the material body includes an aerosol generating material rod, such as a tobacco rod. For example, the material body may include shredded tobacco material. The material body may be formed as a rod. In some embodiments, the material body includes cutrag tobacco formed as a rod. The aerosol generating material may include tobacco material. The aerosol generating material may include extruded tobacco. The aerosol generating material may include reconstituted tobacco.

[0257] Aerosol-generating materials that form as solid materials may include nicotine. Aerosol-generating materials may include tobacco, be composed of tobacco, or be substantially composed of tobacco. In this embodiment, the aerosol-generating material does not contain tobacco.

[0258] In any of the embodiments described above, heating of the article causes a relatively constant release of volatile compounds into the inhalable medium. In any of the embodiments described above, the aerosol-generating segment is a block of material. The article may include a mouthpiece section. A tubular element may be located between the aerosol-generating material and the mouthpiece section. The article may include a ventilation area in the mouthpiece section. The mouthpiece section may define a mouthpiece configured to be placed between the user's lips.

[0259] In embodiments of any of the articles described above, the resistive heating element or the resistive heating elements are configured to substantially heat the entire aerosol-generating material. In embodiments, the aerosol-generating segment is at least substantially cylindrical. In embodiments, the aerosol-generating segment is at least partially enveloped by a resistive heating layer. In embodiments, the resistive heating element extends within the aerosol-generating segment. The resistive heating element may extend around the aerosol-generating segment. In embodiments, the resistive heating element surrounds the aerosol-generating segment. In some configurations, at least a portion of the flow path through the article passes through the aerosol-generating segment. The aerosol-generating segment may define a portion of the air path. In embodiments, first-type electrical contacts and second-type electrical contacts are exposed from the aerosol-generating segment.

[0260] Aerosol-generating materials may include the tobacco materials described herein, which include tobacco components. In the tobacco materials described herein, the tobacco components may contain paper-reconstituted tobacco. The tobacco components may also contain tobacco leaves, extruded tobacco, and / or bandcast tobacco. The tobacco materials may be provided in the form of shredded tobacco. Shredded tobacco may be formed from mixtures of tobacco materials, such as one or more of paper-reconstituted tobacco, tobacco leaves, extruded tobacco, and bandcast tobacco. In embodiments, the tobacco materials include paper-reconstituted tobacco or a mixture of paper-reconstituted tobacco and tobacco leaves. In the tobacco materials described herein, the tobacco materials may contain filler components. Filler components are typically non-tobacco components, i.e., components that do not include tobacco-derived ingredients. Filler components may be non-tobacco fibers, such as wood fibers or pulp or wheat fibers. Filler components may also be inorganic materials, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, or magnesium carbonate. The filler component may also be a non-tobacco casting material or a non-tobacco extruded material. The filler component may be present in an amount of 0 to 20% by weight of the tobacco material, or in an amount of 1% to 10% by weight of the composition. In some embodiments, the filler component is absent. In the tobacco materials described herein, the tobacco material contains an aerosol-forming agent material. In this context, "aerosol-forming agent material" is an agent that promotes aerosol generation. Aerosol-forming agent materials can promote aerosol generation by promoting initial vaporization and / or promoting the condensation of gases into inhalable solid and / or liquid aerosols. In some embodiments, the aerosol-forming agent material can improve the delivery of flavoring agents from the aerosol-generating material. Generally, the aerosol-generating material of the present invention may include any suitable aerosol-forming agent material or agent, including those described herein.

[0261] Paper-based reconstituted tobacco refers to tobacco material formed through the following process: extracting tobacco raw materials with a solvent to obtain an extract of soluble substances and a residue including fibrous material; and then recombining the extract and fibrous material by depositing the extract (usually a concentrated extract, and optionally a further processed extract) onto the fibrous material from the residue (usually a finely ground fibrous material, and optionally a fibrous material with some non-tobacco fibers added). The recombining process is similar to a papermaking process.

[0262] The various embodiments described herein are presented only to aid understanding and teach the claimed features. These embodiments are provided as representative examples only and are not exhaustive or / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or on equivalents thereof, and other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or substantially consist of suitable combinations of disclosed elements, components, features, portions, steps, members, etc., other than those specifically described herein. Additionally, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. An aerosol generator for an aerosol supply device, the aerosol generator comprising: Aerosol generating materials; as well as A resistive heating layer includes a resistive heating element configured to heat at least a portion of the aerosol-generating material to generate an aerosol; Wherein, the resistive heating element is at least a portion of the conductive path between the first type of electrical contact and the second type of electrical contact; and The resistive heating layer includes multiple surface features.

2. The aerosol generator according to claim 1, wherein, The plurality of surface features include a plurality of perforations.

3. The aerosol generator according to claim 1 or 2, wherein, The plurality of surface features includes at least one of a plurality of indentations and a plurality of protrusions.

4. The aerosol generator according to any one of claims 1 to 3, wherein, At least some of the surface features are formed along the conductive path.

5. The aerosol generator according to claim 4, wherein, The plurality of surface features are configured to at least partially determine the resistance along the conductive path.

6. The aerosol generator according to any one of claims 1 to 5, comprising an array of the surface features.

7. The aerosol generator according to any one of claims 1 to 7, comprising an aerosol generating layer, the aerosol generating layer comprising the aerosol generating material.

8. The aerosol generator according to claim 7, wherein, The aerosol generating layer includes multiple aerosol generating layer perforations.

9. The aerosol generator according to claim 8, wherein, The plurality of surface features of the resistive heating layer are aligned with the plurality of perforations in the aerosol generating layer.

10. The aerosol generator according to any one of claims 7 to 9, wherein, The aerosol generating layer is non-perforated.

11. The aerosol generator according to any one of claims 1 to 10, comprising a support member configured to support the resistive heating layer.

12. The aerosol generator according to claim 11, wherein, The support component has no perforations.

13. The aerosol generator according to claim 11, wherein, The support member includes multiple support holes.

14. The aerosol generator according to claim 13, wherein, The plurality of surface features of the resistive heating layer are aligned with the plurality of support perforations.

15. The aerosol generator according to any one of claims 1 to 16, wherein, At least one resistance heating element has at least one of the following: a resistance different from that of another resistance heating element, and a plurality of surface features different from those of another resistance heating element.

16. An aerosol generator, comprising: An aerosolizable layer, incorporating an aerosolizable material; as well as A conductive layer in contact with the aerosolizable layer, wherein the conductive layer includes a plurality of perforations, and wherein the conductive layer includes one or more heating elements, wherein the heating elements or each of the heating elements provides a conductive path for resistively heating a portion of the aerosolizable material to generate an aerosol, wherein the heating elements or each of the heating elements extends from a first type of electrical connection to a second type of electrical connection.

17. An article comprising an aerosol generator according to any one of claims 1 to 16.

18. An aerosol supply device configured to receive an aerosol generator according to any one of claims 1 to 16 or an article according to claim 17.

19. An aerosol supply system, comprising: The aerosol generator according to any one of claims 1 to 16 or the article according to claim 17; as well as An aerosol supply device configured to receive the aerosol generator or the article.

20. A blank for forming an aerosol generator for an aerosol supply device, comprising: A resistive heating layer, wherein the resistive heating layer forms a heating element, the heating element providing a conductive path for resistive heating; Type I electrical contacts; and Second type of electrical contact; The heating element extends between the first type of electrical contact and the second type of electrical contact, and The resistive heating layer includes multiple surface features.

21. A method comprising: Forming a resistance heating layer including resistance heating elements; An aerosol-generating material is provided on the resistive heating layer; wherein the resistive heating element is configured to heat at least a portion of the aerosol-generating material to generate an aerosol; Wherein, the resistive heating element is at least a portion of the conductive path between the first type of electrical contact and the second type of electrical contact; and Multiple surface features are formed on the resistive heating layer.

22. A method comprising: The conductive layer is formed as one or more heating elements, each of which provides a conductive path for resistive heating of a portion of an aerosolizable material to generate an aerosol. as well as The formed conductive layer is placed in contact with the aerosolizable layer, wherein the aerosolizable layer is bonded with the aerosolizable material. in: The heating element, or each of the heating elements, extends from a first type of electrical connection to a second type of electrical connection; and The conductive layer includes multiple perforations.

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