Aerosol generator

Abstract

An aerosol generator (304) is provided. The aerosol generator includes an aerosol-generating material (302), a resistive heating layer (340) configured to heat the aerosol-generating material, and a support layer (350) having a support. The resistive heating layer is on the first side of the support. The resistive heating layer includes at least one of the first type of electrical contacts and at least one of the second type of electrical contacts. At least one of the first type of electrical contact and the second type of electrical contact can be accessed from the second side of the support.

Description

Technical Field

[0001] This invention relates to an aerosol generator for an article of an aerosol supply device. The invention also relates to an article of an aerosol supply device, an aerosol supply system, a method for forming an aerosol generator for an article of an aerosol supply device, and a blank for forming an aerosol generator for an article of an aerosol supply device. Background Technology

[0002] Smoking articles such as cigarettes, cigars, and the like burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles by manufacturing products that release compounds without combustion. Examples of such products are so-called "heat-not-burn" products or tobacco heating devices or products that release compounds by heating but not burning a material. This material can be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.

[0003] Aerosol supply systems encompassing the aforementioned devices or products are known. Common systems use a heater to generate an aerosol from a suitable medium, which is then inhaled by a user. Typically, it is necessary to replace or change the medium used to provide different aerosols for inhalation. Resistance heating systems are known to be used as heaters to generate aerosols from a suitable medium. Summary of the Invention

[0004] According to one aspect, an aerosol generator for an aerosol supply device is provided, the aerosol generator comprising: an aerosol generating material; 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; the aerosol generating material being located on the resistance heating layer; a first type of electrical contact; a second type of electrical contact; wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact; and a support member, wherein the resistance heating layer is located on a first side of the support member, between the aerosol generating material and the support member; wherein at least one of the first type of electrical contact and the second type of electrical contact is accessible from a second side of the support member.

[0005] In any of the embodiments described above, the aerosol generator includes an aerosol generating layer comprising an aerosol generating material. In any of the embodiments described above, the aerosol generating layer is located on the resistance heating layer.

[0006] In any of the above embodiments, the resistance heating layer does not contain folds.

[0007] In any of the above embodiments, the support member does not contain a folded portion.

[0008] In any of the above embodiments, the support includes a support layer.

[0009] In any of the above embodiments, the support is electrically insulated.

[0010] In any of the above embodiments, the support includes paper or card.

[0011] In any of the above embodiments, the conductive layer and the support layer define the substrate.

[0012] In any of the above embodiments, the aerosol generator includes a laminate comprising a resistance heating layer and a support layer.

[0013] In any of the above embodiments, the laminate includes an aerosol-generating material.

[0014] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact can be accessed from the second side of the support.

[0015] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact is exposed from the second side of the support.

[0016] In any of the above embodiments, the support layer includes a card layer.

[0017] In any of the above embodiments, the second side is opposite to the first side.

[0018] In any of the above embodiments, the first type of electrical contact is configured to be electrically connected to the device electrical connector, and the second type of electrical contact is configured to be electrically connected to the device electrical connector.

[0019] In any of the above embodiments, the support defines an exposed contact area for the first type of electrical contact.

[0020] In any of the above embodiments, the exposed contact area is a first exposed contact area, and the support defines a second exposed contact area, which is an exposed contact area of ​​a second type of electrical contact.

[0021] In any of the above embodiments, the aerosol generation layer is a continuous aerosol generation layer.

[0022] In any of the above embodiments, the aerosol generation layer is a discontinuous aerosol generation layer.

[0023] In any of the above embodiments, the aerosol generating layer includes a plurality of separate aerosol generating portions.

[0024] In any of the above embodiments, the resistance heating element is one of a plurality of resistance heating elements.

[0025] In any of the above embodiments, one of these separate aerosol generating portions is associated with a corresponding resistance heating element among a plurality of resistance heating elements.

[0026] In any of the above embodiments, the aerosol generating layer includes at least one of dots, strips, and patches.

[0027] In any of the above embodiments, the resistance heating element is a first heating element and the resistance heating layer is formed with a second resistance heating element, each resistance heating element providing a conductive path for resistance heating of a portion of the aerosol generating material to generate aerosol at a corresponding portion of the aerosol generating layer.

[0028] In any of the above embodiments, the resistance heating layer forms an array of resistance heating elements, including at least a first resistance heating element and a second resistance heating element.

[0029] 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 respectively.

[0030] In any of the embodiments above, the aerosol generating layer includes a membrane or gel layer containing an aerosol generating material.

[0031] In any of the above embodiments, the aerosol generator includes a plurality of first-type electrical contacts, wherein each of the plurality of heating elements includes an independent first-type electrical contact.

[0032] In any of the embodiments above, the aerosol generator includes a plurality of second-type electrical contacts, wherein each of the plurality of resistance heating elements includes an independent second-type electrical contact.

[0033] In any of the above embodiments, the aerosol generator includes a single second-type electrical contact.

[0034] In any of the above embodiments, the single second-type electrical contact is shared among each of the plurality of resistance heating elements.

[0035] In any of the above embodiments, the resistance heating element is formed by at least one of the following: cutting the resistance heating layer; chemically etching the resistance heating layer; forming or pressing the resistance heating layer in the substrate; and printing the resistance heating layer.

[0036] In any of the above embodiments, the resistance heating layer is in the form of a foil.

[0037] In any of the above embodiments, the aerosol generator includes an opening in the support such that at least one of the first type of electrical contact and the second type of electrical contact can be accessed from a second side of the support.

[0038] In any of the above embodiments, the opening includes an orifice in the support.

[0039] In any of the above embodiments, the opening is a cut in the support.

[0040] In any of the above embodiments, the opening extends from the edge of the support.

[0041] In any of the above embodiments, the support member includes a first surface and a second surface of the support member.

[0042] In any of the above embodiments, the opening extends between the first surface and the second surface of the support.

[0043] In any of the above embodiments, the opening is configured to receive at least a portion of the device connector of the aerosol supply device.

[0044] In any of the above embodiments, each of the first type of electrical contact and the second type of electrical contact is configured to be connected to the device electrical connector.

[0045] In any of the above embodiments, the support defines an exposed contact area for at least one of the first type of electrical contact and the second type of electrical contact.

[0046] In any of the above embodiments, the support defines separate exposed contact areas for each of the first type of electrical contact and the second type of electrical contact.

[0047] In any of the above embodiments, the opening defines a common opening between at least two exposed contact areas of at least one of the first type of electrical contact and the second type of electrical contact.

[0048] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact extends at least partially through the support.

[0049] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact extends at least partially through the support to be exposed at a second side of the support.

[0050] In any of the above embodiments, the aerosol generator includes a path in the support through which at least one of a first type of electrical contact and a second type of electrical contact extends.

[0051] In any of the above embodiments, the path includes an opening through the support member, and at least one of the first type of electrical contact and the second type of electrical contact extends around the sidewall of the opening.

[0052] In any of the above embodiments, the orifice extends through the resistance heating layer.

[0053] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact extends around the edge of the orifice.

[0054] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact extends partially through the support.

[0055] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact extends completely through the support.

[0056] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact extends beyond the second side of the support.

[0057] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact includes a conductive coating.

[0058] In any of the embodiments described above, the conductive coating comprises conductive ink.

[0059] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact overlaps with the second side of the support.

[0060] According to one aspect, an article of articles comprising an aerosol generator according to any of the above embodiments is provided.

[0061] According to one aspect, an aerosol supply system is provided, comprising an aerosol generator according to any of the above embodiments and an aerosol supply device configured to receive the aerosol generator.

[0062] According to one aspect, an aerosol supply system is provided, comprising an article of any of the above embodiments and an aerosol supply device configured to receive the article.

[0063] According to one aspect, a method is provided for forming an aerosol generator for an aerosol supply device, the method comprising: providing a resistance heating layer; providing an aerosol generating material on the resistance heating layer, wherein the resistance heating layer includes a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; providing a first type of electrical contact; providing a second type of electrical contact; wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact; providing a support member; providing the resistance heating layer on a first side of the support member, between the aerosol generating material and the support member; wherein at least one of the first type of electrical contact and the second type of electrical contact can be accessed from a second side of the support member.

[0064] In any of the embodiments above, the method includes: providing an aerosol generation layer that protects the aerosol generation material.

[0065] In any of the above embodiments, the method includes forming an opening in the support such that at least one of a first type of electrical contact and a second type of electrical contact can be accessed from a second side of the support.

[0066] In any of the above embodiments, at least one of the first type of electrical contact and the second type of electrical contact is formed to extend at least partially through the support member.

[0067] According to one aspect, an aerosol supply system is provided, comprising: an article and an aerosol supply device configured to receive at least a portion of the article, the article comprising: an aerosol generating material; 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; the aerosol generating material being located on the resistance heating layer; a first type of electrical contact; a second type of electrical contact; wherein the resistance heating element forms at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact; and a support member, wherein the resistance heating layer is located on a first side of the support member, between the aerosol generating material and the support member; wherein at least one of the first type of electrical contact and the second type of electrical contact is accessible from a second side of the support member.

[0068] In any of the embodiments described above, the aerosol generator includes an aerosol generating layer comprising an aerosol generating material. In any of the embodiments described above, the aerosol generating layer is located on a resistance heating layer.

[0069] In any of the embodiments above, the aerosol supply device includes a device electrical connector configured to connect to at least one of a first type of electrical contact and a second type of electrical contact.

[0070] In any of the above embodiments, the device electrical connector includes a connector electrical contact configured to connect from a second side of the support to at least one of a first type of electrical contact and a second type of electrical contact.

[0071] In any of the above embodiments, the device electrical connector includes a piercing element configured to pierce a feature portion of the article.

[0072] In any of the above embodiments, the feature portion of the article includes a support member, and the piercing element is configured to pierce the support member to electrically contact at least one of a first type of electrical contact portion and a second type of electrical contact portion.

[0073] In any of the above embodiments, the connector electrical contact includes a piercing element.

[0074] In any of the above embodiments, the piercing element is a pin.

[0075] In any of the above embodiments, the piercing element is configured to pierce the resistive heating layer to contact at least one of the first type of electrical contact and the second type of electrical contact.

[0076] In any of the above embodiments, the piercing element is configured to pierce the support to contact at least one of the first type of electrical contact and the second type of electrical contact.

[0077] In any of the embodiments above, the aerosol supply device includes a receiving cavity configured to receive at least a portion of the article, and the connector electrical contact portion is located in the receiving cavity.

[0078] In any of the above embodiments, the receiving cavity is configured to locate at least one of a first type of electrical contact and a second type of electrical contact.

[0079] In any of the above embodiments, the piercing element comprises a conductive material.

[0080] In any of the above embodiments, the piercing element can be moved to engage with the article through piercing.

[0081] In any of the embodiments above, the article can be moved to engage with the piercing element.

[0082] In any of the above embodiments, the piercing element supplies power to the resistance heating layer.

[0083] According to one aspect, a blank for forming an aerosol generator for an aerosol supply device is provided, the blank comprising: a resistance heating layer including a resistance heating element configured to heat at least a portion of an aerosol generating material to generate an aerosol; a first type of electrical contact; a second type of electrical contact; wherein the resistance heating element forms at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact; and a support member, wherein the resistance heating layer is located on a first side of the support member between the aerosol generating material and the support member; and an opening in the support member such that at least one of the first type of electrical contact and the second type of electrical contact can be accessed from a second side of the support member.

[0084] In any of the above embodiments, the blank includes an aerosol generating layer comprising an aerosol generating material.

[0085] According to one aspect, an aerosol generator for an aerosol supply device is provided, the aerosol generator comprising: an aerosol generating material; 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; a first type of electrical contact; and a second type of electrical contact; wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact.

[0086] According to one aspect, an article of articles comprising an aerosol generator according to any of the above embodiments is provided.

[0087] According to one aspect, an aerosol supply system is provided, comprising an aerosol generator according to any of the above embodiments, and an aerosol supply device configured to receive the aerosol generator. Attached Figure Description

[0088] Various implementations will now be described with reference to the accompanying drawings and by way of example only, in which: Figure 1 This is a schematic 3D diagram of an aerosol supply system; Figure 2 It includes Figure 1A schematic three-dimensional diagram of an aerosol-generating material product from an aerosol supply system; Figure 3 yes Figure 2 A schematic perspective view of the first side of the aerosol generator for the product; Figure 4 yes Figure 3 A schematic perspective view of a portion of the second side of an aerosol generator; Figure 5 Such as Figure 1 A schematic block diagram of the aerosol supply system of the system shown; Figure 6 yes Figure 2 A schematic partially exploded perspective view of the product, in which the aerosol generator is shown as an inverted orientation from the assembly and spaced apart from the other components; Figure 7 Such as Figure 3 A schematic cross-sectional view of another aerosol generator shown in the diagram; Figure 8 yes Figure 3 A schematic plan view of the heating element of an aerosol generator; Figure 9 It has multiple heating elements Figure 3 A schematic plan view of the resistance heating layer of an aerosol generator; Figure 10 It shows an aerosol generator (such as...) Figure 3 A flowchart of a method for generating an aerosol generator; Figure 11 This is an exploded 3D view of an aerosol generator in the process of formation. Figure 12 This is a schematic 3D view of the resistance heating layer of the forming aerosol generator; Figure 13 It shows an aerosol generator (such as...) Figure 3 A flowchart of a method for generating an aerosol generator; Figure 14 It shows an aerosol generator (such as...) Figure 3 A flowchart of a method for generating an aerosol generator; Figure 15 It shows an aerosol generator (such as...) Figure 3 A flowchart of a method for generating an aerosol generator; Figure 16 This is a schematic 3D view of the resistance heating layer of the forming aerosol generator; Figure 17 This is a schematic plan view of the heating element of an aerosol generator; Figure 18 This is a schematic plan view of the heating element of an aerosol generator; Figure 19 yes Figure 2 A schematic perspective view of a portion of the aerosol generator for the product; Figure 20 yes Figure 1 A schematic perspective view of the connector of the aerosol supply device in an aerosol supply system; Figure 21 yes Figure 1 A schematic side view of an aerosol generation system; Figure 22 It shows an aerosol generator (such as...) Figure 3 A flowchart of a method for generating an aerosol generator; Figure 23 This is a schematic plan view of the first side of the aerosol generator for the product; Figure 24 This is a schematic cross-sectional view of the aerosol generator for the product; Figure 25 yes Figure 24 An exploded view of a schematic cross-sectional view of the aerosol generator of the product shown; Figure 26 This is a schematic cross-sectional view of the aerosol generator for the product; Figure 27 This is a schematic diagram of an aerosol supply system; and Figure 28 yes Figure 26 An enlarged view of the aerosol supply system. Detailed Implementation

[0089] As used herein, the term "delivery mechanism" is intended to encompass systems that deliver substances to users and includes: non-flammable aerosol supply systems that release compounds from aerosolized materials without combustion, such as electronic cigarettes, tobacco heating products, and mixing systems, to generate aerosols using combinations of aerosolized materials; and articles comprising aerosolized materials and configured for use in one of these non-flammable aerosol supply systems.

[0090] According to this disclosure, a "non-flammable" aerosol supply system is an aerosol supply system in which the aerosol generating material is non-flammable or non-ignitable and delivers at least one substance to the user.

[0091] In some implementations, the delivery system is a non-flammable aerosol supply system, such as a powered non-flammable aerosol supply system.

[0092] In some implementations, the non-flammable aerosol supply system is an electronic cigarette, also known as a vapor device or electronic nicotine delivery system (END); however, it should be noted that the presence of nicotine in the aerosol generating material is not necessary.

[0093] In some implementations, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a heated non-combustible system. An example of such a system is a tobacco heating system.

[0094] In some embodiments, the non-flammable aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to generate aerosols, wherein one or more of these aerosol-generating materials can be heated. Each aerosol-generating material may be in the form of a solid, liquid, or gel, 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.

[0095] 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.

[0096] In some embodiments, this disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-flammable aerosol supply devices. These consumables are sometimes referred to as articles in this disclosure.

[0097] In some implementations, the 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.

[0098] In some embodiments, a non-flammable aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, nozzles, filters, and / or aerosol modifiers.

[0099] 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 conveying component, aerosol generator, aerosol generating area, housing, packaging paper, filter, nozzle, and / or aerosol modifier.

[0100] As used herein, the term "aerosol-generating material" (which is sometimes referred to herein as aerosolizable material) is a material that is capable of generating aerosols, for example, when supplied with energy by heating, radiation, or any other means. Aerosol-generating materials may be in the form of, for example, solid, liquid, or semi-solid (e.g., gel), and may or may not contain active substances and / or flavorings.

[0101] In some implementations, the substance to be delivered includes an active substance (sometimes referred to herein as an active compound).

[0102] 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.

[0103] 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 and cocoa.

[0104] 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.

[0105] In some implementations, the substance to be delivered includes a flavoring agent.

[0106] 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.

[0107] In some embodiments, in addition to or in place of aroma or taste receptors, flavoring agents may include sensory agents designed to achieve somatic sensations typically induced and perceived by chemical stimulation of the fifth cranial nerve (trigeminal nerve), and these may include agents that provide heating, cooling, tingling, or numbing effects. Suitable heat-effecting agents may be, but are not limited to, vanillyl ether, and suitable coolants may be, but are not limited to, eucalyptol, WS-3.

[0108] 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.

[0109] Aerosol-generating materials may include binders (such as gelling agents) and aerosol-forming agents. Optionally, a substance to be transported and / or a filler may also be present. Optionally, a solvent (such as water) may also be present, and one or more other components of the aerosol-generating material may be soluble in the solvent or insoluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. Specifically, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0110] 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 transported and / or fillers 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.

[0111] 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.

[0112] Aerosol-generating membranes can be continuous. For example, the membrane can comprise or be a continuous sheet of material.

[0113] Aerosol-generating membranes can be discontinuous. For example, an aerosol-generating membrane may comprise one or more separate 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.

[0114] In one embodiment, the aerosol-generating material includes a plurality of aerosol-generating membranes. In another embodiment, the aerosol-generating membrane includes a plurality of aerosol-generating membrane regions. Such plurality of aerosol-generating membranes and / or aerosol-generating membrane regions may have different properties, such as different compositions, thicknesses, densities, active substances and / or flavors, one or more aerosol-forming agent materials, and optionally at least one of one or more other functional materials.

[0115] 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 transported) to form a slurry, and then heating the slurry to atomize at least some of the solvent to form an aerosol-generating membrane.

[0116] The slurry can be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent.

[0117] The aerosol-generating material can be an "amorphous solid." In some embodiments, the amorphous solid is a "monolithic solid." The aerosol-generating material can be non-fibrous or fibrous. In some embodiments, the aerosol-generating material can be a dried gel. The aerosol-generating material can be a solid material that can retain some fluid (such as a liquid) within it. In some embodiments, the retained fluid can be water (such as water absorbed from the surrounding environment of the aerosol-generating material) or the retained fluid can be a solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent can be water.

[0118] Aerosol forming agent materials may include one or more components capable of forming aerosols. In some embodiments, the aerosol forming agent material may include one or more of glycerol, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl octanoate, triethyl citrate, triacetin, a mixture of glycerol diacetate, benzyl benzoate, benzyl phenyl acetate, glyceryl tartrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0119] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers and / or antioxidants.

[0120] The material may be present on or within the support to form a matrix. The support may be, or include, for example, paper, cardboard, cardboard, reconstituted materials, plastic materials, ceramic materials, composite materials, glass, metal, or metal alloys.

[0121] An aerosol supply device can receive an article containing aerosol-generating material for heating. In this context, an "article" is a component that includes or contains aerosol-generating material and optionally includes or contains other components in use, which is heated to atomize the aerosol-generating material. A user can insert the article into or onto an aerosol supply device, after which the article is heated to generate an aerosol, which the user then inhales.

[0122] 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 heat energy in order to release one or more volatiles from the aerosol generating material to form an aerosol.

[0123] Consumables are articles containing or composed of aerosol-generating materials, which are intended in whole or in part for consumption by a user during use. Consumables may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol delivery component, an aerosol-generating area, a housing, a package, a nozzle, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which releases heat during use to cause the aerosol-generating material to generate an aerosol. The heater may include a conductor that is heated by an electric current passing through it.

[0124] A non-flammable aerosol supply system may include modular components having both a reusable aerosol supply device and a replaceable aerosol generating article. In some embodiments, the non-flammable aerosol supply device may include a power source and a controller (or control circuitry). The power source may, for example, include an electric power source, such as a battery or a rechargeable battery. In some embodiments, the non-flammable aerosol supply device may also include an aerosol generating component. However, in other embodiments, the aerosol generating article may partially or completely comprise the aerosol generating component.

[0125] Figure 1 A schematic diagram of an aerosol supply system 100 is shown. The aerosol supply system 100 includes an aerosol supply device 200 and an article 300 containing aerosol generating material 302 (see reference). Figure 3 ).exist Figure 2 The image shows the article 300 being removed from the aerosol supply device 200. The aerosol generator 304 of the article 300 is in... Figure 3 The first side 306 is shown in the perspective view. Figure 4 A perspective view of a portion of the second side 307 is shown in the middle.

[0126] Article 300 includes an aerosol generator 304. The aerosol generator 304 is configured to generate aerosol from aerosol generating material 302 during operation of the aerosol supply system 100, as will be described in detail below.

[0127] The aerosol supply system 100 is elongated and extends along a longitudinal axis. The aerosol supply system 100 has a proximal end 102 and a distal end 104, the proximal end being closest to the user (e.g., the user's mouth) when the user inhales the aerosol generated by the aerosol supply system 100, and the distal end being furthest from the user during use.

[0128] The proximal end can also be referred to as the "mouth tip". The aerosol supply system 100 accordingly defines a proximal direction, i.e., the direction pointing towards the user during use. Furthermore, the aerosol supply system 100 similarly defines a distal direction, i.e., the direction away from the user during use. The terms "proximal" and "distal" applied to features of the system 100 will be described with reference to the relative positioning of such features to each other in the proximal-distal direction along the longitudinal axis.

[0129] Article 300 is received by aerosol supply device 200. The configuration of article 300 and aerosol supply device 200 can vary. In this embodiment, aerosol supply device 200 includes a device body 202. The device has a housing 204 that encloses the components of device 200. Figure 5 As shown, the device chamber 206 is configured to receive part of the article 300. When the article 300 is received in the device chamber 206, the proximal end 308 of the article protrudes from the device 200. A receiving cavity 208 defines the chamber 206. The receiving cavity 208 includes a receiving cavity base 210 and a receiving cavity peripheral wall 212. The configuration of the receiving cavity 208 can vary depending on the configuration of the article 300.

[0130] One or more user-operable control elements 224, such as buttons or switches, may be provided on the aerosol supply device 200 for operating the aerosol supply system 100. For example, a user can activate the system 100 by pressing the control element 224. One or more user-operable control elements may be omitted. In an embodiment, the aerosol supply system 100 is operated by another user action, such as suction initiated by the user drawing air through the system.

[0131] The aerosol supply device 200 includes an opening 214 at its proximal end leading to a device chamber 206. The opening 214 is disposed in one end through which an article 300 can be inserted. In an embodiment, the article 300 can be fully or partially inserted into the device 200. The configuration of the device 200 can vary; for example, the opening may be located in the longitudinal sidewall of the device 200, and / or may be closed during use by another feature of the device 200. In the current configuration, the article 300 defines a mouthpiece 310 at its proximal end 308. In an embodiment, the device 200 defines the mouthpiece. The user places their mouth over the mouthpiece during use.

[0132] Device 200 defines a longitudinal axis along which article 300 can extend when inserted into device 200. Opening 214 is aligned along the longitudinal axis.

[0133] The aerosol supply device 200 includes a power source 220. The power source 220 may be a battery, such as a rechargeable battery. The device 200 also includes a control circuit 222, which acts as a controller and includes a processor and memory.

[0134] As discussed in detail below, the heating system 110 is configured to heat the aerosol-generating material 302 of the article 300. In this embodiment, the article 300 is a consumable and interchangeable with other articles 300. The heating system 110 includes an aerosol generator 304. The heating system 110 includes other components of the aerosol supply system 100, including components of the article 300 and the aerosol supply device 200, such as the power supply 220 and the control circuitry 222.

[0135] Aerosol generator 304 forms part of article 300. Aerosol generator 304 includes heating device 312 configured to heat aerosol generating material 302 (e.g., at least one of a membrane and gel for generating aerosols). Aerosol generating material may be referred to as aerosolizable material.

[0136] The heating device 312 is a resistance heating device. The resistance heating device includes a plurality of heating elements as described below. Each heating element is a resistance heating element, as described in detail below. In such a device, the heating system 110 includes a resistance heating generator that includes components for heating the heating device 312 via a resistance heating process. In this case, current is applied directly to the resistance heating element, and the induced current flow in the heating element (acting as the heating component) causes the heating element to be heated by Joule heating. The resistance heating element comprises a resistive material configured to generate heat when a suitable current passes through it, and the heating device 312 includes electrical contacts for supplying current to the resistive material. Providing the resistance heating device 312 allows for a compact configuration. Resistance heating provides an efficient configuration.

[0137] In use of the aerosol supply system 100, air is drawn into the air inlet 314 of the article 300, as indicated by arrow 316. The air inlet 314 is located at the distal end of the article 300. In embodiments, the air inlet 314 may have different configurations, such as on the side. The airflow into the air inlet 314 of the article 300 may be defined, for example, by at least one of the following: an air path through the device 200, an air path located outside the device 200, and an air path located between the device 200 and the article 300. The aerosol generated by the aerosol generator 304 exits the article at the aerosol outlet 318, as indicated by arrow 319. In embodiments, the aerosol outlet 318 is located in the mouthpiece of the article 300, such that the aerosol is drawn directly from the article 300 into the mouth of the user of the system 100.

[0138] In some exemplary embodiments, the aerosol supply system includes two main components: a control section forming a reusable portion and a consumable section forming a replaceable or disposable portion, which may be referred to as a replaceable or disposable article or cartridge. As described herein, the aerosol supply device 200 forms the control section, and the article 300 forms the consumable section. In use of the aerosol generation system, the control section and the consumable portion can be releasably connected at an interface. For example, when using the consumable portion, the consumable portion can be removable and replaceable, wherein the control section is reused along with different consumable portions.

[0139] The aerosol supply system 100 shown is provided by way of example only and is highly illustrative. Different aerosol generating devices and other devices may be used in exemplary embodiments of the principles described herein. For example, in some exemplary embodiments, air is drawn into an air inlet in a control section, passes through an interface, and exits the consumable section.

[0140] like Figure 5 As schematically shown and described in detail below, article 300 has an article electrical contact configuration 320. In an embodiment, the electrical contact configuration 320 is formed by an aerosol generator 304. The electrical contact configuration 320 includes a heater electrical contact 322. The heater electrical contact 322 may also be referred to as a heater or an article contact. The aerosol supply device 200 includes an electrical connector 230. The electrical connector 230 includes a connector electrical contact 232. The connector electrical contact 232 may also be referred to as a connector or a device contact. The article electrical contact configuration 320 is configured to be electrically connected to the device electrical connector 230.

[0141] The configuration of the product 300 can be varied. The product 300 includes a body 324. The body 324 is hollow. The body 324 defines a flow path 326 through the product 300 (see reference). Figure 6 Flow path 326 extends between air inlet 314 and aerosol outlet 318. Flow path 326 is defined by an internal space within the article along which air and / or aerosol can flow. Flow path 326 is defined within body 324. The aerosol generator or each aerosol generator 304 limits flow path 326. Aerosol generating material 302 is exposed to flow path 326. Aerosol generating material 302 is exposed within the internal space. In an embodiment, the internal space comprises two or more chambers.

[0142] The air inlet 314 includes an opening 315. The opening 315 is formed in the body 324. In an embodiment, the opening is formed in another component of the article 300, such as the aerosol generator 304 or another wall feature. The aerosol outlet 318 includes an outlet opening 317. The outlet opening 317 is formed in the body 324. In an embodiment, the outlet opening 317 is formed in another component of the article 300, such as the aerosol generator 304 or another wall feature.

[0143] like Figure 6 As shown, article 300 includes two aerosol generators 304 forming an aerosol generator apparatus. The number of aerosol generators 304 may vary. Each aerosol generator 304 contains aerosol generating material 302. The aerosol generating material 302 is exposed to a flow path 326. In one embodiment, article 300 includes a single aerosol generator 304. One aerosol generator 304 will be described in detail, while this detail applies to one or more other aerosol generators 304 in various embodiments.

[0144] The aerosol generator, or each aerosol generator 304 and body 324, is formed in a stacked configuration. Other configurations, such as tubular configurations of articles of manufacture, are contemplated in embodiments. In such tubular configurations, the aerosol generator 304 defines the tubular configuration. The tubular shape may include a circular cross-section and other polygonal shapes.

[0145] In one embodiment, as shown in the accompanying drawings, the article 300 has a flat configuration. That is, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and width, wherein the length is greater than or equal to the width, and wherein the width is greater than the depth. Other configurations are also conceivable.

[0146] Figure 6 This is a partially exploded perspective view of article 300, in which aerosol generator 304 is shown in an inverted orientation from assembly and spaced apart from other components. Article 300 includes a first aerosol generator 302, a body 324, and a second aerosol generator. The body 324 spaces the first and second aerosol generators 304 apart. The first and second aerosol generators 304 enclose an internal space defined by the body 324, along which air and / or aerosols can flow. The aerosol generating materials 302 of the first and second aerosol generators 304 face each other and are exposed to the internal space. When assembled, the first and second aerosol generators 304 sandwich the body 324. At least in Figure 6In one embodiment, the first and second aerosol generators 304 and the body have the same planar area. In another embodiment, one or more of the first and second aerosol generators 304 and the body 324 have a greater length and / or width. In yet another embodiment, one of the first and second aerosol generators 304 is replaced by a spare panel. The body 324 includes body layers. The body may comprise multiple body layers. The body layers may be formed in a stacked manner and arranged to define various features of the article 300, such as the air inlet 314 and the aerosol outlet 318.

[0147] The covering 390 surrounds the article 300 and forms part of the article 300, for example, see reference. Figure 25 The cover 390 is a sheet. The cover 390 acts as a retaining sleeve. The aerosol generator, or each aerosol generator 304, protrudes from the cover 390 at its distal end. The exposed electrical contact area 323 of the heater contact 322 is exposed at its distal end. Other configurations are conceivable, for example, at least one exposed electrical contact area 323 may additionally or alternatively be defined along a smaller longitudinal face or edge of the article 300 and on the main face of the article defined by the aerosol generator 304.

[0148] Aerosol generator 304 Figure 7 The cross-section is shown schematically. The aerosol generator 304 is an embodiment of the aerosol generator 304 of the aerosol supply system 100 described above.

[0149] Aerosol generator 304 includes an aerosol generating layer 330. The aerosol generating layer is also referred to as an aerosolizable layer. The aerosol generating layer 330 contains an aerosol generating material 302. Aerosol generator 304 includes a resistance heating layer 340. In one embodiment, the resistance heating layer 340 is formed as a conductive layer. The aerosol generating layer 330 is located on the resistance heating layer 340. The aerosol generating layer 330 is in direct contact with the resistance heating layer 340. In another embodiment, the aerosol generating layer 330 is in indirect contact with the resistance heating layer 340. In another embodiment, the resistance heating layer 340 may include a coating. As described in detail below, the resistance heating layer 340 includes a plurality of resistance heating elements 342, for example... Figure 8 and Figure 9 As shown, the resistance heating element, or each resistance heating element 342, forms at least a portion of a conductive path between a pair of electrical contacts 322. The resistance heating element, or each resistance heating element 342, provides a conductive path for resistively heating at least a portion of the aerosol generating material 302, thereby generating an aerosol. In an embodiment, the aerosol generating material 302 is in the form of a film or gel.

[0150] The resistance heating layer 340 is formed as a conductive layer. In an embodiment, this layer is in the form of at least one of a metallic layer (such as an aluminum layer) or a non-metallic material (such as graphene). The resistance heating layer 340 is in the form of a foil, such as an aluminum foil.

[0151] The aerosol generator 304 includes a support member 350. In some embodiments, the support member 350 comprises paper or card material. The support member 350 provides structural support to the aerosol generator 304. A resistance heating layer 340 is located on the support member 350. The support member 350 is configured as a support layer. Figure 7 As shown, in the aerosol generator 304, the resistance heating layer 340 is sandwiched between the support 350 and the aerosol generating layer 330.

[0152] The support 350 is electrically insulated. The resistance heating layer 340 and the support layer 350 define the substrate 352. The substrate 352 supports the aerosol generation layer 330.

[0153] Article 300 includes a laminate 354, which includes a resistance heating layer 340 and a support layer 350. In one embodiment, the laminate 354 includes an aerosol generating layer 330. The aerosol generating layer 330 may be formed in a continuous configuration or may be formed from discrete portions. The discrete portions may include one or more of dots, strips, spirals, or other shapes.

[0154] In one embodiment, the aerosol generating layer 330 includes an aerosol generating membrane. In another embodiment, the aerosol generating layer 330 includes a plurality of aerosol generating membranes. In yet another embodiment, the aerosol generating membrane includes a plurality of aerosol generating membrane regions. These plurality of aerosol generating membranes and / or aerosol generating membrane regions may have different characteristics, such as different compositions, thicknesses, densities, active substances and / or flavors, one or more aerosol forming agent materials, and optionally at least one of one or more other functional materials.

[0155] One or more of the aerosol generating layer 330, the resistance heating layer 340, and the support layer 350 may include another layer. For example, the support layer 350 may include a backing layer or an intermediate layer. In this embodiment, the support layer 350 is omitted.

[0156] Figure 8 One of the resistance heating elements 342 is shown. The resistance heating layer 340 includes a plurality of resistance heating elements 342. In an embodiment, the resistance heating layer 340 includes a single resistance heating element 342.

[0157] Multiple heating elements 342 are formed in Figure 9 The array 344 shown is an example. Other configurations are conceivable.

[0158] The resistance heating element 342 includes a resistance heating path. The resistance heating path is formed by a conductive path. The resistance heating path is not straight. The resistance heating path is tortuous. The configuration of the resistance heating path can vary. The resistance of the heating element 342 can depend on the characteristics of the resistance heating path in the conductive layer, such as the path's length, width, thickness, and arrangement.

[0159] A resistance heating element 342 extends between a first-type electrical contact 360 and a second-type electrical contact 365. The first-type electrical contact 360 is configured to provide a positive contact, and the second-type electrical contact 365 is configured to provide a negative contact. Current flows through a path between the first-type electrical contact 360 and the second-type electrical contact 365. The arrangement of the contacts can be interchanged. The first-type and second-type electrical contacts constitute the heater electrical contact 322. The first-type electrical contact 360 and the second-type electrical contact 365 form at least a portion of the article electrical contact configuration 320.

[0160] Compared to a straight path between the first type of electrical contact and the second type of electrical contact, the tortuous or serpentine nature of the path of the resistance heating element 342 increases the resistance of the path.

[0161] The resistance heating layer 340 includes a first-type electrical track 361 extending from the resistance heating element 342. The first-type electrical track 361 includes a first-type electrical contact 360. The first-type electrical contact 360 is configured for electrical connection with the device electrical connector 230. The first-type electrical contact 360 includes a first-type exposed contact area 362. The first-type exposed contact area 362 is exposed on the article of manufacture for direct connection with the device electrical connector 230.

[0162] The resistance heating layer 340 includes a second type of electrical track 366 extending from the resistance heating element 342. The second type of electrical track 366 includes a second type of electrical contact 365. The second type of electrical contact 365 is configured for electrical connection with the device electrical connector 230. The second type of electrical contact 365 includes a second type of exposed contact area 367. The second type of exposed contact area 367 is exposed on the article 300 for direct connection with the device electrical connector 230.

[0163] As discussed in detail below, in one embodiment, the conductive path of the resistance heating element 342 is formed by defining at least one electrically insulating barrier 346 in the resistance heating layer 340. In one embodiment, the electrically insulating barrier 346 is formed by cutting barrier constraints (i.e., electrically insulating portions), such as gaps, channels, or slots, into a sheet made of an electrically conductive material used to form the resistance heating layer 340. In one embodiment, the resistance heating layer 340 is pre-formed to define the resistance heating element or each resistance heating element 342 and then applied to the support 350. In one embodiment, the resistance heating layer 340 is applied to the support 350, and the resistance heating element or each resistance heating element 342 is then defined in the resistance heating layer 340. The resistance heating element or each resistance heating element 342 defining the resistance heating layer 340 may be a printed heater. The insulating barrier may be an air gap. In one embodiment, the insulating barrier is a filled gap, for example, filled with an insulating material. This barrier defines a barrier that prevents current from crossing it.

[0164] The resistance heating element or each resistance heating element 342 defining the resistance heating layer 340 can be formed by a cutting action. Cutting may include die cutting. The resistance heating element can be formed by an action applied only to the resistance heating layer. In an embodiment, the resistance heating element can be formed by an action applied to both the resistance heating layer and the support layer (e.g., an action of cutting the resistance heating layer and the support layer).

[0165] At least one electrical insulation barrier 346 defines a first type of electrical track 361 and a second type of electrical track 366.

[0166] In some embodiments, the tracks of the resistance heating element or each resistance heating element 342 have a width of approximately 0.5 mm to 1 mm (the two prototype examples 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 prototype examples have gaps of 0.2 mm and 0.05 mm, respectively). The resistance heating element or each resistance heating element 342 may have an overall size of approximately 10 mm × 10 mm. Other sizes are possible in other exemplary embodiments. By forming these sizes of resistance heating elements or each resistance heating element 342 with aluminum foil of 0.006 mm thickness and 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 measurement is between 0.83 Ohm and 1.31 Ohm.

[0167] like Figure 9As shown, the resistance heating layer 340 is formed as a plurality of resistance heating elements, generally indicated by reference numerals 342a, 342b, 342c, 342d, and 342e. Each of the resistance heating elements 342a to 342e extends from a separate electrical contact of the first type (generally indicated by reference numerals 360a, 360b, 360c, 360d, and 360e) to a single electrical contact of the second type 365. The number of electrical contacts can vary. Thus, each resistance heating element 342a to 342e extends between separate first-type electrical contacts and a common second-type electrical contact.

[0168] Each of the resistance heating elements 342a to 342e provides a conductive path for resistively heating a portion of the aerosol generating material 302 to generate an aerosol at a corresponding portion of the aerosol generator 304.

[0169] Independent first-type electrical contacts 360a to 360e allow current to be supplied separately to each of the plurality of resistance heating elements 342a to 342e. Heating of different zones of the aerosol generation layer 330 can be controlled. For example, the aerosol generator may be provided with five aerosol generation zones. The resistance heating layer 340 allows each of these zones to be activated individually. Thus, for example, a single consumable containing a single aerosol generator 304 can generate five aerosols, and a single consumable containing two aerosol generators 304 can generate ten aerosols.

[0170] In the exemplary resistance heating layer 340, a plurality of first-type electrical contacts 360a to 360e (e.g., positive electrical connections) are provided, and a single second-type electrical contact 365 (e.g., negative electrical connection) is provided. This is not necessary for all embodiments. For example, a plurality of second-type contacts may be provided. In an embodiment, each resistance heating element 342a to 342e includes a corresponding one of the first-type electrical contacts 360 and a corresponding one of the second-type electrical contacts 365.

[0171] exist Figure 9 In the embodiment of the resistance heating layer 340 shown, first-type electrical contacts 360a to 360e are arranged on the first edge 363 of the resistance heating layer 340, and second-type electrical contacts 365 are arranged on the second edge 368 of the resistance heating layer 340. This allows for convenient electrical connection, but of course, many other configurations are possible, some of which are discussed further below.

[0172] Figure 10 This is a flowchart illustrating a portion of a method or algorithm (generally indicated by reference numeral 400) for forming an aerosol generator 304 according to an exemplary embodiment.

[0173] Method or algorithm 400 begins at operation 402, where a resistance heating layer is formed as one or more heating elements (e.g., a plurality of heating elements), wherein each resistance heating element extends from a first type of electrical contact to a second type of electrical contact. In use, the heating element or each heating element can be used to provide a conductive path for resistively heating a portion of the aerosol-generating material to generate an aerosol. The formation of the resistance heating element or each resistance heating element can occur before or after the resistance heating layer is applied to a support (where a support is present). The resistance heating layer can be attached to the support, or mounted or formed on the support in different configurations.

[0174] At operation 404, the formed resistance heating layer is placed in contact with the aerosol generation layer, wherein the aerosol generation layer contains aerosol generation material.

[0175] Figure 11 An aerosol generator 304 formed according to an embodiment is shown. Aerosol generating material 302 is formed on the resistance heating layer 340 by deposition of the aerosol generating material (e.g., by spraying, brushing, dispensing, or some other method). In an exemplary embodiment of operation 404, the aerosol generating layer 330 is disposed on the resistance heating layer 340, as indicated by arrow 406.

[0176] Figure 12 A resistance heating layer 340 formed according to an exemplary embodiment is shown. The resistance heating layer 340 is being cut using a laser cutter 408. The cutting of the resistance heating layer 340 can be used to form the path of the heating element described herein. The use of a laser cutter 408 (or some other cutting process) is not the only way to generate the resistance heating layer 340 described herein. Some exemplary methods will be described below.

[0177] Figure 13 This is a flowchart illustrating a portion of a method or algorithm (generally indicated by reference numeral 410) for forming an aerosol generator 304. The method or algorithm 410 begins at operation 412, where a resistance heating layer is provided. At operation 414, one or more resistance heating elements are formed in the resistance heating layer by chemical etching. Operations 412 and 414 are exemplary embodiments of operation 402 of the method 400 described above. Aerosol-generating material is then placed on the resistance heating layer, thereby implementing operation 404 as described above.

[0178] Figure 14This is a flowchart illustrating a portion of a method or algorithm (generally indicated by reference numeral 418) for forming an aerosol generator 304. The method or algorithm 418 begins at operation 420, where one or more heating elements are at least partially formed by printing a resistance heating layer. Operation 420 is therefore an exemplary embodiment of operation 402 of the algorithm 400 described above. Aerosol-generating material is then placed on the resistance heating layer, thereby implementing operation 404 as described above.

[0179] The cutting, etching, and printing methods described above are provided with the aid of examples; other additional or alternative methods are also possible. For example, a so-called "thermal transfer foil" method can be used, in which the heating element is made of a resistance heating layer and then assembled / bonded to a support. Other techniques, such as die-cutting, can still be used. Furthermore, two or more techniques can be combined (e.g., conductivity can be added to the connection traces by adding more conductive material, such as additional foil, printing material, etc.). Those skilled in the art will recognize that many other techniques or combinations of techniques can be used in embodiments of the principles described herein.

[0180] Figure 15 This is a flowchart illustrating an operational method or algorithm (generally indicated by reference numeral 424) according to an exemplary embodiment. Method or algorithm 424 can be implemented, for example, using any of the aerosol generators described herein. Method or algorithm 424 begins upon receiving a command to initiate heating, as in the example of operation 426. In response to the command to initiate heating, a determination is made regarding the availability of heating elements (in operation 428). As discussed above, multiple heating elements may be provided. Operation 428 may involve determining which heating elements have been used and / or the corresponding available aerosol generating material has been exhausted.

[0181] If a heating element is available, the algorithm moves to operation 430, where the available heating element is used. As discussed above, the heating elements can be controlled independently, for example, by supplying power to each individual heating element. After operation 430 is completed, the algorithm terminates at operation 432. If, at operation 428, it is determined that no heating element is available, for example because all heating elements are in use, the algorithm terminates at operation 432. This refers to the need to replace the consumable portion used to implement algorithm 424.

[0182] Figure 16 A resistance heating layer 340 formed according to an embodiment is shown. The resistance heating layer 340 is cut using a laser cutter 408, but other methods, such as chemical etching or printing discussed above, may also be used. The conductive layer 340 is cut to form the heating element described herein.

[0183] exist Figure 16 In this embodiment, the cut path is a linear path extending along the length of the conductive layer 120.

[0184] Figure 17 Another embodiment of the resistance heating layer 340 is shown. The resistance heating layer 340 can be formed using the laser cutter 408 described above or similar devices or other methods. The resistance heating layer 340 includes a plurality of resistance heating elements 342, each of which is a linear heating element comprising a conductive path extending along the length of the resistance heating layer 340. Each resistance heating element 342 extends from one of a first type of electrical contact 360 (e.g., a positive electrical connection) to one of a second type of electrical contact 365 (e.g., a negative electrical contact). In this embodiment, both types of electrical contacts are disposed at the same end of the resistance heating layer 340 and are arranged adjacent to each other. In this arrangement, unlike in some other embodiments, there is no common second type of electrical contact; instead, each heating element has independent first and second type electrical contacts.

[0185] Figure 18 Another embodiment of the resistance heating layer 340 is shown. The resistance heating layer 340 can be formed using the laser cutter 408 described above or some similar apparatus or other method. The resistance heating layer 340 includes a plurality of heating elements 342, each heater assembly 342 including a linear heating element along a conductive path extending along the length of the resistance heating layer 340. Each resistance heating element 342 extends from one of a first type of electrical contact 360 (e.g., a positive electrical connection) to a second type of electrical contact 365 (e.g., a negative electrical contact). In this embodiment, different types of electrical connections are provided at opposite ends of the resistance heating layer 340, and a common second type of electrical contact is provided. Although configured as a linear path, resistance can be increased by means of configuring a creneled path, which acts as a tortuous path. It should be noted that the paths of any other embodiments described herein can also be creneled.

[0186] Figure 19 The distal end of article 300 is shown. As shown, body 324 includes a plurality of body layers 325. Body layers 325 are arranged in a stack. Body layers 325 form a laminate. In an embodiment, body layer 325 is a card layer. Other suitable materials may be used. Body layers 325 are configured to define features of article 300. In an embodiment, at least one body layer includes a gap defining an air inlet 315. This gap defines an opening 314.

[0187] The aerosol generator 304 includes a resistance heating layer 340. The resistance heating layer 340 includes resistance heating elements 342, a first type of electrical contact 360 providing a positive electrical connection to each of the plurality of heating elements 342, and a single second type of electrical contact 365 providing a common negative electrical connection to the plurality of heating elements 342. The first type of electrical contact 360 and the second type of electrical contact 365, i.e., heater contact 322, together form at least a portion of the article electrical contact configuration 320 of the aerosol generator 304.

[0188] The resistance heating element 342 contacts the aerosol generation layer 330 on the inward surface 341 of the resistance heating layer 340, for example, reference... Figure 24 The resistance heating layer 340 at least partially defines Figure 3 The aerosol generator 304 shown is located on its first side 306. The heater contact 322 is situated on the outward surface 343 of the resistance heating layer 340, for example, referenced to... Figure 24 The heater contact 322 is exposed on the second side 307 of the aerosol generator 304. An outer surface 343 defines a portion of the second side of the aerosol generator 304. The heater contact 322 is exposed such that it can contact the device electrical connector 230. The heater contact 322 is exposed on the side of the resistance heating layer 340 opposite to the resistance heating element 342. Other configurations are conceivable.

[0189] The heater contact portion 322 is exposed on the side of the support layer 350 opposite to the resistance heating layer 340 itself. In this embodiment, the support layer 350 does not contain folds. This helps simplify the manufacture of the aerosol generator 304.

[0190] The support layer 350 defines a first-type exposed contact area 362. The support layer 350 defines a second-type exposed contact area 367. The heater contacts 322 of the first-type electrical tracks 361 and the second-type electrical tracks 366 are exposed on a second side of the resistance heating layer 340. Some portions of the first-type electrical tracks 361 and the second-type electrical tracks 366 extend on a first side of the resistance heating layer 340.

[0191] The aerosol supply device 200 includes a plurality of connector electrical contacts 232 of an electrical connector 230. The configuration of the device connector 230 depends on the configuration of the heater contacts 322 of the aerosol generator 304. In situations such as... Figure 19In the embodiment of the aerosol generator shown, the aerosol generator 300 includes a plurality of accessible heater contacts 322, which include one of a plurality of first-type heater contacts 360 and a second-type heater contacts 365. The article 300 includes another set of heater contacts 322 on the opposite side of the article 300 corresponding to the second aerosol generator 304.

[0192] Figure 20 A device connector 230 for use in an aerosol supply device 200 in some embodiments is shown. The connector 230 has a separate connector electrical contact 232 for connection with a heater contact 322.

[0193] Figure 21 An aerosol supply system 100 is schematically shown. System 100 includes an article 300 and an aerosol supply device 200, both shown in block diagram. Device 200 includes a first connector 230a and a second connector 230b.

[0194] When the article 300 is inserted into the aerosol supply device 200, connectors 230a and 230b enable the aerosol supply device 200 to supply regulated or controlled voltage and / or current to the respective first-type heater contacts 360 and second-type heater contacts 365 of the aerosol generator 304. The aerosol supply device 200 may include connector configurations configured to supply power to connectors 230a and 230b. The aerosol supply device 200 may operate, for example, the method described above.

[0195] Figure 22 This is a flowchart illustrating a method or algorithm (generally indicated by reference numeral 440) for forming an aerosol generator 304 according to an exemplary embodiment.

[0196] Method or algorithm 440 begins at operation 442, where a resistance heating layer is formed as at least one resistance heating element, which, or each heating element, provides a conductive path for resistance heating of at least a portion of an aerosolizable material to generate an aerosol. Exemplary heating elements that may be formed in operation 442 are described elsewhere in this document.

[0197] At operation 442, an aerosol generating material is applied and / or formed on the resistance heating layer 340.

[0198] Operations 442 and 444 of method or algorithm 440 are similar to (and may be equivalent to) operations 402 and 404 of method or algorithm 400 described above.

[0199] In operation 446, at least one first-type electrical contact is disposed on the resistance heating layer. The forming method can be any of the methods described above. In operation 448, at least one second-type electrical contact is disposed on the resistance heating layer. The forming method can be any of the methods described above.

[0200] The first and second types of electrical contacts can be formed along or near a single edge of the resistance heating layer. In embodiments, the first and second types of electrical contacts can be formed along or near different edges of the resistance heating layer.

[0201] A first type of electrical contact (e.g., one or more positive connections) may be disposed along a first edge of the resistance heating layer. A second type of electrical contact (e.g., one or more negative connections) may be disposed along a second edge of the resistance heating layer. Operations 446 and 448 may be performed in different orders or simultaneously. Furthermore, operations 446 and 448 may be performed together with operation 442.

[0202] At operation 450, a support member 350 is provided. A resistance heating layer 340 is disposed on a first side 355 of the support member 350, between the aerosol generating layer 330 and the support member 350. At least one first-type electrical contact 360 and a second-type electrical contact 365 are accessible from a second side 356 of the support member 350.

[0203] In one embodiment, operation 450 of method 400 includes forming an opening 358 in the support 350 such that at least one of the first type of electrical contact 360 and the second type of electrical contact 365 can be accessed from a second side 356 of the support 350 through the opening 358, thereby forming an aerosol generator as described with reference to any of the embodiments of the above aerosol generator.

[0204] Method 400 may further include: forming at least one of the first type of electrical contact 360 and the second type of electrical contact 365 to extend at least partially through the support member 350.

[0205] like Figure 7 , Figure 23 , Figure 24 and Figure 25 As seen, for example, support member 350 includes a first side 355 and a second side 356. A resistance heating layer 340 is located on the first side 355 of support member 350 and between support member 350 and aerosol generating layer 330. Support member 350 includes a first surface 375 on the first side 355 and a second surface 376 on the second side 356. After assembly, the second side 356 of support member 350 defines the exposed side of article 300.

[0206] The support member 350 and the resistance heating layer 340 do not contain folds. Both the resistance heating layer 340 and the support member 350 are planar bodies. In some embodiments, folds are formed in one or both of the support member 350 and the resistance heating layer 340. By limiting the folds in the resistance heating layer 340, the resistivity of each feature portion of the resistance heating layer 340 can be more reliably controlled.

[0207] The first type of electrical contact 360 and the second type of electrical contact 365 can be accessed from the second side 356 of the support member 350. In some instances, all or some of the plurality of first type electrical contacts 360 can be accessed from the second side 356 of the support member. Alternatively or concurrently, all or some of the plurality of second type electrical contacts 365 can be accessed from the second side 356 of the support member 350.

[0208] The first type of electrical contact 360 and the second type of electrical contact 365 are exposed from the second side 356 of the support 350. The support 350 defines at least one exposed contact area of ​​either the first type of electrical contact 360 or the second type of electrical contact 365. The first side 306 of the aerosol generator 304 is covered by other components of the article 300, such as the body 324 of the article 300. Figure 6 and Figure 23 As illustrated in the diagram.

[0209] "Exposed" means that the electrical contact portion is able to make electrical contact with another component on the second side 356 of the support 350. Therefore, the device electrical connector contact portion 232 can be connected to this electrical contact portion. The exposed contact area is one of a first type of exposed contact area 362 or a second type of exposed contact area 367. In this example, the support 350 defines separate exposed contact areas for each of the first type of electrical contact portion 360 and the second type of electrical contact portion 365.

[0210] The first type of electrical contact 360 and the second type of electrical contact 365 are configured to connect to the device electrical connector 230, enabling the device 200 to supply power to the resistance heating layer 340. The first type of electrical contact 360 and the second type of electrical contact 365 are configured to connect to the device electrical connector contact 232, providing an electrical connection between the device 200 and the first type of electrical contact 360 and the second type of electrical contact 365. Current is supplied from the power source 220 to each resistance heating element 342 through the electrical connection between the device 200 and the first type of electrical contact 360 and the second type of electrical contact 365.

[0211] like Figure 23 , Figure 24 and Figure 25As seen, the support member 350 includes an opening 358 to allow the first type of electrical contact 360 and the second type of electrical contact 365 to be accessed from the second side 356 of the support member 350. The first type of electrical contact 360 and the second type of electrical contact 365 can be accessed through the support member 350. The opening 358 extends between the first surface 375 and the second surface 376 of the support member 350. In one embodiment, the opening 358 may include an aperture in the support member 350 that surrounds the first type of electrical contact 360 and the second type of electrical contact 365 and allows access only from the second surface 376 of the support member 350. In another embodiment, the opening 358 may be a cut in the support member 350 that extends from the edge of the support member 350 and allows access to the first type of electrical contact 360 and the second type of electrical contact 365 from the side of the support member 350 and the second surface 376 of the support member 350. In another embodiment, the opening 358 may be formed together with the support member 350 during manufacturing. In an implementation, the opening 358 may be formed, for example, by drilling, grinding, or cutting.

[0212] In one embodiment, the covering 390 extends above the support 350. The covering 390 covers the second surface 376, such as... Figure 25 As shown in the diagram. In this configuration, the cover 390 includes a cover opening 391. The cover opening 391 is aligned with an opening 358 in the support 350.

[0213] In one embodiment, the cover 390 comprises multiple layers, and the cover opening 391 is formed through these multiple layers. In another embodiment, the support 350 includes the cover, and / or the cover acts as the support 350.

[0214] In an implementation, the opening 358 can be cylindrical, rectangular, or any other shape.

[0215] The opening 358 is configured to receive at least a portion of the device electrical connector 230, such that the device electrical connector 230 is at least partially disposed within the opening 358. When at least a portion of the device electrical connector 230 is received in the opening 358, the device electrical connector contact 232 contacts at least one of a first type of electrical contact 360 and a second type of electrical contact 365, such as... Figure 24 and Figure 25 As seen in the text.

[0216] Opening 358 defines a common opening between at least two exposed contact areas, such that both the first type of electrical contact 360 and the second type of electrical contact 365 can be accessed through this common opening. In one embodiment, support 350 may include a plurality of openings 358. Support 350 may include one opening 358 for each of the first type of electrical contact 360 and the second type of electrical contact 365. In another embodiment, support 350 may include a single opening 358 for all first type of electrical contacts 360 and a second opening 358 for all second type of electrical contacts.

[0217] In one embodiment, a plurality of openings 358 may be spaced regularly along the support member 350. The openings 358 may be spaced along the length of the support member 350, i.e., repeating along the longest dimension of the support member. The openings 358 may be spaced along the width of the support member 350, i.e., repeating along the second longest dimension of the support member. In another embodiment, the openings 358 may be positioned along the side of the support member 350.

[0218] like Figure 26 As seen, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends at least partially through the support member 350. In an embodiment, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends completely through the support member 350, for example in... Figure 26 As seen in the embodiment. In this embodiment, the first type of electrical contact 360 and the second type of electrical contact 365 extend through the support member 350. In this embodiment, the first type of electrical contact 360 and the second type of electrical contact 365 extend completely through the support member 350. By extending at least partially through the support member 350, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 can be accessed from the second side 356 of the support member 350. In this embodiment, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends completely through the support member 350 and is exposed on the second side 356 of the support member.

[0219] The support member 350 includes a path 380 through which at least one of a first type of electrical contact 360 and a second type of electrical contact 365 extends. The path 380 is formed by an aperture 381. In one embodiment, the path 380 is formed by a hole or opening in the support member 350. In another embodiment, the aperture 381 extends through the support member 350 and through the resistance heating layer 340.

[0220] At least one of the first type electrical contact 360 and the second type electrical contact 365 extends around at least a portion of the sidewall of the aperture 381. At least one of the first type electrical contact 360 and the second type electrical contact 365 extends around the edge of the aperture. In one embodiment, at least one of the first type electrical contact 360 and the second type electrical contact 365 extends only around the sidewall of the aperture 381, or extends around the sidewall and around at least one of the first and second edges of the aperture 381. In one embodiment, at least one of the first type electrical contact 360 and the second type electrical contact 365 extends completely through the support 350. In one embodiment, at least one of the first type electrical contact 360 and the second type electrical contact 365 extends through the support 350 and extends beyond the second side 356 of the support 350. In one embodiment, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends completely through the support 350, extends beyond the second side 356 of the support, and extends on the second surface 376 of the support 350. At least one of the first type of electrical contact 360 and the second type of electrical contact 365 may overlap with the second side 356 of the support 350. In another embodiment, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 partially extends through the support 350.

[0221] At least one of the first type of electrical contact 360 and the second type of electrical contact 365 includes a conductive coating. In an embodiment, the conductive coating may include conductive ink. The conductive ink is in liquid form when applied, thereby making it easier to apply to the path 380, such as to the sidewalls of the orifice, the edges of the orifice, and the second surface of the support 350.

[0222] In one embodiment, one or more of the device electrical connector contacts 232 may be attached to at least one of a first type of electrical contact 360 and a second type of electrical contact 365 to provide an electrical connection between the device electrical connector 230 and the resistance heating layer 340. The device electrical connector contacts 232 may be attached to a conductive coating.

[0223] An aerosol supply system 500 is also disclosed. The aerosol supply system includes an article 300 and an aerosol supply device 200. In embodiments, the article 300 and the aerosol supply device 200 may be as described above.

[0224] like Figure 27 As seen, the device 200 is configured to receive at least a portion of the article 300. The device 200 receives a portion of the article 300 such that a portion of the article 300 protrudes from the device 200. In an embodiment, the device 200 may receive the entire article 300.

[0225] Article 300 includes an aerosol generating layer 330 comprising an aerosol generating material 302. Article 300 also includes a resistance heating layer 340 including a resistance heating element 342 configured to heat at least a portion of the aerosol generating material 302 to generate an aerosol. The aerosol generating layer 330 is located on the resistance heating layer 340. Article 300 also includes a body 324.

[0226] The article 300 further includes at least one of the first type of electrical contacts 360 and at least one of the second type of electrical contacts 365. In an embodiment, at least one of the first type of electrical contacts 360 and the second type of electrical contacts 365 may be as described above. The resistance heating element 342 forms a conductive path between the first type of electrical contacts 360 and the second type of electrical contacts 365.

[0227] The article 300 further includes a support member 350. A resistance heating layer 340 is disposed on a first side 355 of the support member 350, such that it is sandwiched between the aerosol generating layer 330 and the support member 350. At least one of a first type of electrical contact 360 and a second type of electrical contact 365 can be accessed from a second side 356 of the support member 350.

[0228] Device 200 includes a device electrical connector 230 that receives power from a power source 220. In one embodiment, device 200 may include a plurality of device electrical connectors 230. The device electrical connectors 230 are configured to connect to at least one of a first type of electrical contact 360 and a second type of electrical contact 365. In another embodiment, the device may include a device electrical connector 230 configured to connect to the first type of electrical contact 360 and a second device electrical connector 230 configured to connect to the second type of electrical contact 365. The device electrical connector 230 includes a device connector electrical contact 232 configured to connect to at least one of the first type of electrical contact 360 and the second type of electrical contact 365. The device connector electrical contact 232 is made of a conductive material.

[0229] The device electrical connector 230 includes a piercing element 240, for example... Figure 27 and Figure 28As seen in the diagram. The piercing element 240 is configured to pierce a feature portion of the article 300. This feature portion includes a support member 350. In one embodiment, the feature portion may include the support member 350 and a resistance heating layer 340. In one embodiment, the feature portion may include a body 324. In one embodiment, the feature portion may include an aerosol generating layer 330. The piercing element 240 is configured to pierce the support member 350 such that it passes through the support member 350 and contacts at least one of a first-type electrical contact 360 and a second-type electrical contact 365. Therefore, the piercing element 240 acts as a device connector electrical contact 232. The piercing element 240 electrically contacts at least one of the first-type electrical contact 360 and the second-type electrical contact 365 when contacting at least one of them. In one embodiment, each of the device connector electrical contacts 232 is a piercing element.

[0230] The piercing element 240 includes a pin. The piercing element 240 includes a conductive material. In an embodiment, the piercing element 240 may include metal. The piercing element 240 is configured to pierce the support 350 to contact at least one of a first-type electrical contact 360 and a second-type electrical contact 365. In an embodiment, the piercing element 240 may be configured to pierce the resistance heating layer 340 to contact at least one of the first-type electrical contact 360 and the second-type electrical contact 365. In an embodiment, a plurality of device electrical connectors 230 may each include a piercing element 240. Figure 27 As shown, the device 200 includes a piercing element 240 for each of at least one of the first type of electrical contacts 360 and at least one of the second type of electrical contacts 365. In one embodiment, each piercing element 240 may be configured to form an electrical connection with one of the first type of electrical contacts 360 or one of the second type of electrical contacts 365. In another embodiment, each piercing element 240 may be configured to pierce a support member 350 such that it contacts either the first type of electrical contact 360 or the second type of electrical contact 365.

[0231] The apparatus includes a receiving cavity 208 configured to receive an article 300. The article 300 is partially received by the receiving cavity 208 such that at least a portion of the article 300 protrudes from the receiving cavity. In an embodiment, the article 300 may be received entirely by the receiving cavity 208. When the article 300 is received in the receiving cavity 208, a piercing element 240 pierces the article 300, such that an electrical connection is formed between the piercing element 240 and at least one of a first-type electrical contact 360 and a second-type electrical contact 365.

[0232] The piercing element 240 is movable to engage with the article 300 through piercing. The piercing element 240 is positioned on a movable plate 250 disposed in a receiving cavity 208, the movable plate 250 being configured to move relative to the device 200 toward the article 300 when the article 300 is received in the receiving cavity 208. The movable plate 250 is disposed in the peripheral wall 212 of the receiving cavity or in the base 210 of the receiving cavity. The movable plate 250 is configured to automatically move toward the article (in direction A) in response to the article 300 being received in the receiving cavity. In an embodiment, the receiving cavity 208 may further include a sensor configured to detect the article 300 being received in the receiving cavity 208. In response to detecting the article 300 being received in the receiving cavity 208, the sensor may send a signal indicating that the article 300 is received in the receiving cavity 208 to a processor. In response to receiving the signal, the processor may send an actuation signal to an actuator mechanically connected to the movable plate 250. In response to receiving an actuation signal, the actuator moves the movable plate 250 toward the article 300 received in the receiving cavity 208.

[0233] The receiving cavity 208 includes Figure 28 The pressure plate 260 is shown. When received in the receiving cavity 208, the article 300 presses against the pressure plate 260 (in direction B). The pressure plate 260 is connected to the movable plate 240. In an embodiment, the pressure plate is mechanically connected to the movable plate 240 via a linkage mechanism. The linkage mechanism can be configured to transfer the force applied to the pressure plate 260 to the movable plate 250. When the pressure plate 260 is pressed, the movable plate 250 moves toward the article 300 placed in the receiving cavity 208, such that the piercing element 240 engages with the support member 350.

[0234] In one embodiment, the device 200 includes a button that acts as a user-operable actuator. The user can actuate the button to move the movable plate 250 toward the article 300 when it is received in the receiving cavity 208, causing the piercing element 240 to engage with the support 350. The button may be electrically connected to a motor configured to actuate the piercing element 240. If the user wishes to remove the article 300 from the receiving cavity, the user can actuate the button a second time to move the piercing element 240 away from the article 300.

[0235] In one embodiment, a retaining element is provided in the receiving cavity 208, which secures the article 300 in place when it is received in the receiving cavity 208. The piercing element 240 moves toward the retaining element. When the article 300 is received in the receiving cavity 208, the movable plate 250 moves toward the retaining element so that the article 300 is clamped between the movable plate 250 and the retaining element. The retaining element provides resistance against the movement of the movable plate 250 so that the piercing element engages with the support member 350.

[0236] In this embodiment, the retaining element is movable. The retaining element moves simultaneously with the movable plate 250 to hold the article 300 in place within the receiving cavity 208. The retaining element can move in a direction substantially opposite to that of the movable plate 250. The retaining element and the movable plate 250 can be configured as reciprocating grippers. The movable plate 250 and the retaining element can move after a user actuates a button, as described above, and / or move in response to pressing the pressure plate 260, as described above.

[0237] In one embodiment, the article 300 is movable to engage with the piercing element 240. The piercing element 240 may be fixed to the receiving cavity 208. The piercing element 240 may be disposed on the receiving cavity base 210 or the peripheral wall 212 of the receiving cavity. The piercing element 240 may be fixed to the receiving cavity 208 such that it pierces the article when the article 300 is received in the receiving cavity 208. The piercing element 240 may extend into the device chamber 206 defined by the receiving cavity 208. When the article 300 is received in the receiving cavity 208, the article 300 may occupy the device chamber 206. When the article 300 is inserted into the receiving cavity 208, the article 300 may be pressed against the piercing element 240 such that the piercing element 240 engages with the article 300.

[0238] The piercing element 240 supplies power to the resistance heating layer 340.

[0239] Also disclosed is a blank for forming an aerosol generator 304 for an article 300 for an aerosol supply device 200. The aerosol generator 304 can be any of the aerosol generator 304 described in the foregoing embodiments. The blank includes an aerosol generating layer 330 containing an aerosol generating material 302. The aerosol generating material 302 can be in gel form. The blank further includes a resistance heating layer 340 including a resistance heating element 342. The resistance heating element 342 is configured to heat at least a portion of the aerosol generating material 302 to generate an aerosol.

[0240] The resistance heating layer 340 is cut using the laser cutting machine described previously. The resistance heating layer 340 is formed as a plurality of resistance heating elements 342, but the number may vary and may be one. A plurality of first-type electrical contacts 360 (e.g., positive electrical contacts) are disposed on the conductive layer 340. One or more of second-type electrical contacts 365 (e.g., negative electrical contacts) are also disposed on the resistance heating layer 340. In this embodiment, these contacts are spaced apart from the edges. As discussed above, each of the plurality of heating elements 342 extends from the first-type electrical contact 360 to the second-type electrical contact 365.

[0241] Cutting the resistance heating layer 340 using a laser cutter 408 creates the path for the heating element or each heating assembly 342. As discussed above, laser forming or some other cutting process is not the only method for forming the resistance heating layer 340 described above. Some exemplary alternative methods include chemical etching, die-cutting, and printing.

[0242] The blank includes a support member 350, and a resistance heating layer 340 is located on a first side 355 of the support member, between the aerosol generating layer 330 and the support member 350. The blank includes an opening 358 in the support member 350, which allows access to at least one of a first type of electrical contact 360 and a second type of electrical contact 365.

[0243] In some embodiments of the different configurations of the aerosol generator and article described above, the aerosol generating material is formed in a configuration other than the aerosol generating layer. In some embodiments, the aerosol generating material is in the form of an aerosol generating section. The aerosol generating section typically comprises a solid material. Such solid material can be shredded tobacco. For example, the aerosol generating material configured as an aerosol generating section can include multiple separate aerosol generating material blocks. The aerosol generating material can be separate tobacco material blocks. In some embodiments, the aerosol generating material includes multiple strips, beads, or pellets. In some embodiments, the aerosol generating section is a material plug.

[0244] In one embodiment, the aerosol generating section includes a material body. The aerosol generating material is non-liquid. In such embodiments, 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 shredded 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.

[0245] The aerosol-generating material, formed as a solid, may contain nicotine. The aerosol-generating material may include tobacco, be composed of tobacco, or be substantially composed of tobacco. In this embodiment, the aerosol-generating material does not contain tobacco.

[0246] 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 section is a material plug. 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.

[0247] In any of the embodiments of the articles described above, the resistance heating element or each resistance heating element is configured to substantially heat the entire aerosol-generating material. In an embodiment, the aerosol-generating section is at least substantially cylindrical. In an embodiment, the aerosol-generating section is at least partially covered by a resistance heating layer. In an embodiment, the resistance heating element extends within the aerosol-generating section. The resistance heating element may extend around the aerosol-generating section. In an embodiment, the resistance heating element surrounds the aerosol-generating section. In some configurations, at least a portion of the flow path through the article passes through the aerosol-generating section. The aerosol-generating section may define a portion of an air path. In an embodiment, first-type electrical contacts and second-type electrical contacts are exposed from the aerosol-generating section.

[0248] The aerosol-generating material may comprise the tobacco material described herein, which contains tobacco components. In the tobacco material 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 material may be provided in the form of shredded tobacco. Shredded tobacco may be formed from mixtures of tobacco materials, such as one or more mixtures of paper-reconstituted tobacco, tobacco leaves, extruded tobacco, and bandcast tobacco. In embodiments, the tobacco material includes paper-reconstituted tobacco or a mixture of paper-reconstituted tobacco and tobacco leaves. In the tobacco material described herein, the tobacco material may contain filler components. Filler components are typically non-tobacco components, i.e., components that do not contain ingredients derived from tobacco. 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. Filler components may also be non-tobacco casting materials or non-tobacco extrusion materials. 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. The tobacco material described herein contains an aerosol-forming agent material. In this context, "aerosol-forming agent material" is a formulation that promotes aerosol generation. Aerosol-forming agent materials can promote aerosol generation by promoting initial vaporization and / or condensation of gas into inhalable solid and / or liquid aerosols. In some embodiments, aerosol-forming agent materials can improve the delivery of flavor from the aerosol-generating material. Generally, any suitable aerosol-forming agent material or formulation may be included in the aerosol-generating material of the present invention, including those aerosol-forming agent materials or formulations described herein.

[0249] Paper-based reconstituted tobacco refers to tobacco material formed through a process in which tobacco raw materials are extracted with a solvent to obtain an extract of soluble substances and a residue comprising fibrous material; and subsequently, the extract and the fibrous material are reconstituted by depositing the extract (usually after concentration, and optionally after further processing) onto the fibrous material from the residue (usually after refining the fibrous material, and optionally with the addition of a portion of non-tobacco fibers). The reconstitution process is similar to the process of manufacturing paper.

[0250] The various embodiments described herein are presented solely to aid understanding and teaching of the claimed features. These embodiments are provided only as representative examples of implementation and are not exhaustive or / or exclusive. It should be understood that the advantages, implementations, examples, functions, features, structures, and / or other embodiments 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 appropriate combinations of the disclosed components, elements, features, portions, steps, components, etc., other than those specifically described herein. Furthermore, 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; The resistance heating layer includes a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; The aerosol generating material is located on the resistance heating layer; Type 1 electrical contact; Second type of electrical contact; Wherein, the resistance 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 A support member, wherein the resistance heating layer is located on a first side of the support member, between the aerosol generating material and the support member; In this embodiment, at least one of the first type of electrical contact and the second type of electrical contact can be accessed from the second side of the support.

2. The aerosol generator according to claim 1, wherein, The resistance heating layer does not contain folds.

3. The aerosol generator according to claim 1 or 2, wherein, The support is electrically insulated.

4. The aerosol generator according to any one of claims 1 to 3, comprising an aerosol generating layer containing the aerosol generating material, wherein, The aerosol generation layer is located on the resistance heating layer.

5. The aerosol generator according to any one of claims 1 to 4, wherein, At least one of the first type of electrical contact and the second type of electrical contact can be accessed from the second side of the support.

6. The aerosol generator according to any one of claims 1 to 5, comprising an opening in the support member such that at least one of the first type of electrical contact and the second type of electrical contact can be accessed from the second side of the support member.

7. The aerosol generator according to any one of claims 2 to 6, wherein, The opening is configured to receive at least a portion of the device electrical connector of the aerosol supply device.

8. The aerosol generator according to claim 6 or 7, wherein, The support defines an exposed contact area for at least one of the first type of electrical contact and the second type of electrical contact.

9. The aerosol generator according to any one of claims 1 to 8, wherein, At least one of the first type of electrical contact and the second type of electrical contact extends at least partially through the support.

10. The aerosol generator of claim 9, comprising a path in the support, wherein at least one of the first type of electrical contact and the second type of electrical contact extends through the path.

11. The aerosol generator according to claim 10, wherein, The path includes an opening through the support member, and at least one of the first type of electrical contact and the second type of electrical contact extends around the sidewall of the opening.

12. The aerosol generator according to claim 11, wherein, The orifice extends through the resistance heating layer.

13. The aerosol generator according to any one of claims 9 to 12, wherein, At least one of the first type of electrical contact and the second type of electrical contact includes a conductive coating.

14. The aerosol generator according to any one of claims 9 to 12, wherein, At least one of the first type of electrical contact and the second type of electrical contact overlaps with the second side of the support.

15. A method for forming an aerosol generator for an aerosol supply device, the method comprising: Provides a resistance heating layer; An aerosol generating material is provided on the resistive heating layer, wherein the resistive heating layer includes a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; Provides a first type of electrical contact; Provide a second type of electrical contact; Wherein, the resistance 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; Provide support components; The resistance heating layer is provided on a first side of the support member, between the aerosol generating material and the support member; In this embodiment, at least one of the first type of electrical contact and the second type of electrical contact can be accessed from the second side of the support.

16. An aerosol supply system, comprising: Article and an aerosol supply device configured to receive at least a portion of said article, said article comprising: Aerosol generating materials; The resistance heating layer includes a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; The aerosol generating material is located on the resistance heating layer; Type 1 electrical contact; Second type of electrical contact; Wherein, the resistance 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 A support member, wherein the resistance heating layer is located on a first side of the support member, between the aerosol generating material and the support member; In this embodiment, at least one of the first type of electrical contact and the second type of electrical contact can be accessed from the second side of the support.

17. The aerosol supply system according to claim 16, wherein, The aerosol supply device includes a device electrical connector configured to connect to at least one of a first type of electrical contact and a second type of electrical contact.

18. The aerosol supply system according to claim 17, wherein, The device electrical connector includes a piercing element configured to penetrate a feature portion of the article.

19. The aerosol supply system according to claim 18, wherein, The feature portion of the article includes the support member, and the piercing element is configured to pierce the support member to electrically contact at least one of the first type of electrical contact portion and the second type of electrical contact portion.

20. A blank for forming an aerosol generator for an article for an aerosol supply device, the blank comprising: Aerosol generating materials; The resistance heating layer includes a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; Type 1 electrical contact; Second type of electrical contact; Wherein, the resistance 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 A support member, wherein the resistance heating layer is located on a first side of the support member, between the aerosol generating material and the support member; An opening is located in the support member, such that at least one of the first type of electrical contact and the second type of electrical contact can be accessed from the second side of the support member.

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