Aerosol supply device

Abstract

An aerosol-forming article (110) comprising: a first surface comprising a first aerosol-generating material (306); and a second surface opposite the first surface such that an airflow path is defined between the first surface and the second surface. The second surface comprises a second aerosol-generating material (308). A distance between the first aerosol-generating material (306) and the second aerosol-generating material (308) is at most 4 mm.

Description

Technical Field

[0001] This invention relates to an article for producing aerosols. Background Technology

[0002] Smoking products such as cigarettes and cigars burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these tobacco-burning products by releasing compounds without combustion. An example of such a product is a heating device that releases compounds by heating a material without burning it. This material can be, for example, tobacco or other non-tobacco products that may or may not contain nicotine. Summary of the Invention

[0003] In one aspect, an aerosol-forming article is provided. The aerosol-forming article includes: a first surface containing a first aerosol-generating material; and a second surface opposite the first surface, such that it defines an airflow path between the first and second surfaces. The second surface contains the second aerosol-generating material. The distance between the first and second aerosol-generating materials is at most 4 mm.

[0004] The distance between the first aerosol generating material and the second aerosol generating material can be at most 2.34 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at most 2.2 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at most 2.1 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at most 2.0 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at least 1.3 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at least 1.34 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at least 1.4 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at least 1.54 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at least 1.6 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at least 1.7 mm. The distance between the first aerosol generating material and the second aerosol generating material can be at least 1.84 mm.

[0005] The airflow path between the first and second surfaces at the aerosol-generating material can be unobstructed. The first and / or second surfaces can be substantially planar. The aerosol-forming article may also include an outlet allowing air to flow out of the article between the first and second surfaces. This outlet may have an area of ​​at least 1.75 mm². 2 The airflow path can be unobstructed between the first and second surfaces at the aerosol-generating material.

[0006] In another aspect, an aerosol supply system is provided. The aerosol supply system includes any of the above-described aerosol forming articles, and an aerosol supply device configured to heat the aerosol generating material to generate an aerosol. Attached Figure Description

[0007] The implementation will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1 A side view of the aerosol supply system is shown; Figure 2 A schematic cross-sectional view of the article in a plane parallel to the longitudinal axis of the article is shown; Figure 3 An exploded view of the substrate and aerosol-generating materials is shown; Figure 4A An exploded view of the intermediate layer of the product is shown; Figure 4B A cross-sectional view of the third intermediate layer of the product is shown; Figure 4C A cross-sectional view of the third intermediate layer is shown, illustrating the flow control characteristics; Figure 5 The graph showing the relationship between the gap size and the amount of aerosol carried is presented. Figure 6A The graph shows the relationship between the area of ​​each inlet and the pressure drop; Figure 6B A graph showing the relationship between the size of each inlet and the amount of aerosol transported is presented. Figure 7A The graph shows the relationship between the amount of aerosol transported and products with different characteristics, including different outlet areas; Figure 7B The graph showing the relationship between the amount of aerosol transported and the outlet area is shown. Figure 8 The test results show the production Figure 7A Exploded views of the structural components of each product shown in the data; Figure 9 A graph showing the relationship between articles with different characteristics and the amount of aerosol transported is presented. Figure 10 The test results show the production Figure 9 Exploded views of the structural components of each product shown in the data; and Figure 11 A schematic cross-sectional view of the article in a plane perpendicular to the longitudinal axis of the article is shown. Detailed Implementation

[0008] As used herein, the term "aerosol-generating material" is, for example, a material capable of generating aerosols when heated, radiated, or otherwise stimulated. Aerosol-generating materials can be in, for example, solid, liquid, or gel form, and may or may not contain active substances and / or flavorings. Aerosol-generating materials can include any plant-based material (such as materials containing tobacco), and may include, for example, one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Aerosol-generating materials may also include other non-tobacco products, which may or may not contain nicotine, depending on the product. Aerosol-generating materials can be in, for example, solid, liquid, gel, wax, etc. Aerosol-generating materials can also be, for example, combinations or mixtures of materials. Aerosol-generating materials may also be referred to as "inhalable materials."

[0009] Aerosol-generating materials may include binders and aerosol-forming agents. Optionally, activators and / or fillers 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 or may not be soluble in that solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In some embodiments, the aerosol-generating material is substantially free of tobacco.

[0010] Aerosol-generating materials may include or may be "amorphous solids". Amorphous solids may be "monolithic solids". In some embodiments, amorphous solids may be dried gels. Amorphous solids are solid materials that can retain some fluid (such as liquid) therein. In some embodiments, aerosol-generating materials may, for example, include from about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of amorphous solids.

[0011] Aerosol-generating materials may include aerosol-generating membranes. Aerosol-generating membranes may include or be sheets, which may optionally be shredded to form fragments. Aerosol-generating sheets or fragments may substantially not contain tobacco.

[0012] According to this disclosure, a "non-combustible" aerosol supply system is a system in which the aerosol supply system (or its components) consists of aerosol generating materials that do not burn or ignite in order to facilitate the delivery of at least one substance to a user.

[0013] In some implementations, the delivery system is a non-combustible aerosol supply system, such as an electric non-combustible aerosol supply system.

[0014] In some implementations, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vapor device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not necessary.

[0015] In some implementations, the non-combustible aerosol supply system is a heating system for the aerosol-generating material, also known as a heated but non-combustible system. An example of such a system is a tobacco heating system.

[0016] In some embodiments, the non-combustible aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to generate aerosols, one or more of which can be heated. Each of these aerosol-generating materials can be in, for example, solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the mixing system includes liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0017] Typically, a non-combustible aerosol supply system may include the non-combustible aerosol supply system and consumables used with the non-combustible aerosol supply system.

[0018] In some embodiments, this disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-combustible aerosol supply devices. Throughout the disclosure, these consumables are sometimes referred to as articles.

[0019] In some embodiments, a non-combustible aerosol supply system, such as its non-combustible aerosol supply system, may include a power source and a controller. For example, the power source may be an electrical power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon substrate that can be excited to distribute power as heat to an aerosol generating material or heat transfer material adjacent to the exothermic power source.

[0020] In some embodiments, a non-combustible aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a nozzle, a filter, and / or an aerosol modifier.

[0021] In some embodiments, consumables used with a non-combustible aerosol supply system may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material delivery components, aerosol generators, aerosol generating areas, housings, packaging paper, filters, mouthpieces, and / or aerosol modifiers.

[0022] The aerosol generating apparatus is capable of receiving an article containing aerosol-generating material for heating. As used herein, "article" refers to a component that includes or contains the aerosol-generating material used (which is heated to cause the aerosol-generating material to volatilize), and optionally other components used. A user can heat the article to generate an aerosol after inserting it into the aerosol supply apparatus, and then inhale the aerosol. The article may, for example, have a predetermined or specific size, configured to be disposed within a heating chamber of the apparatus whose dimensions are designed to receive the article.

[0023] refer to Figure 1 The aerosol supply system 10 includes an aerosol supply device 100 for generating aerosols from aerosol generating materials. The aerosol supply system 10 also includes a replaceable article 110 containing the aerosol generating materials. In general, the aerosol forming device 100 can be used to heat the article 110 to generate an aerosol or other inhalable medium to be inhaled by a user of the device 100. In this example, the aerosol forming article 110 is used in conjunction with the aerosol supply device 100. However, in other examples, the aerosol forming article 110 can be used as an aerosol supply device (e.g., in cases where it is a single-use, one-piece aerosol supply system).

[0024] The aerosol forming apparatus 100 includes a body 102. A housing is arranged around and accommodates the various components of the body 102. A product hole 104 is formed at one end of the body 102, through which a product 110 can be inserted for heating by the aerosol generator 200.

[0025] The device 100 may also include a user-operable control element 150, such as a button or switch, which operates the device 100 when pressed. For example, a user can turn on the device 100 by operating the switch 150.

[0026] The aerosol generator 200 defines a longitudinal axis 111 aligned with the axis of the article 110.

[0027] In use, the article 110 can be fully or partially inserted into the aerosol generator 200, in which the article can be heated by one or more components of the aerosol generator.

[0028] Apparatus 100 includes a device for heating an aerosol-generating material. The device includes an aerosol-generating assembly, a controller (control circuitry), and a power source. The device forms part of a body 102. The aerosol-generating assembly is configured to heat the aerosol-generating material of an article 110 inserted through an article hole 104, such that an aerosol is generated from the aerosol-generating material. The power source supplies power to the aerosol-generating assembly, and the aerosol-generating assembly converts the supplied electrical energy into thermal energy for heating the aerosol-generating material. The power source may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries.

[0029] A power source can be electrically connected to the aerosol generating assembly to supply electricity to heat the aerosol generating material when needed and under the control of the controller. The control circuitry can be configured to enable and disable the aerosol generating assembly based on user input. User input can be performed via pressing a button or opening a door of the device (e.g., a door covering a consumable receiving container). The control circuitry can be configured to enable and disable the assembly automatically, for example, when an article is inserted.

[0030] Aerosol generation assemblies may include various components that heat aerosol-generating materials via an induction heating process. Induction heating is a process of heating a conductive heating element (such as a sensor) through electromagnetic induction. An induction heating assembly may include a sensing element (e.g., one or more induction coils) and means for passing a changing current (such as alternating current) through the sensing element. The changing current in the sensing element generates a changing magnetic field. The changing magnetic field penetrates the sensor (heating element) appropriately positioned relative to the sensing element and generates eddy currents within the sensor. The sensor has resistance to the eddy currents, and thus the flow of the eddy currents against this resistance causes the sensor to be heated by Joule heating. In cases where the sensor contains a ferromagnetic material (such as iron, nickel, or cobalt), heat can also be generated through hysteresis losses in the sensor, i.e., by the change in orientation of magnetic dipoles in the magnetic material due to alignment with the changing magnetic field. Compared to heating by, for example, conduction, heat is generated within the sensor in induction heating, thus allowing for rapid heating. Furthermore, no physical contact is required between the sensing element and the sensor, thus allowing for greater freedom in construction and application.

[0031] refer to Figure 2Article 110 further includes a first substrate 302 and a second substrate 304. Both the first substrate 302 and the second substrate 304 are made of aluminum foil-backed high basis weight (GSM) paper (e.g., 70 gsm to 400 gsm or 100 gsm to 400 gsm paper, such as 240 gsm paper) or any paper having a GSM greater than 400 gsm. In some embodiments, the aluminum foil-backed high GSM paper can be considered as aluminum foil-backed high GSM paper. In some embodiments, the high GSM paper can have a thickness of 0.125 mm or 0.35 mm. In other embodiments, the high GSM paper can have a greater or lesser thickness. In some embodiments, the first and second substrates 302, 304 can be considered as a double-layer material, such as a card or paper backed with a metal surface. In other words, the first and / or second substrates 302, 304 each include an aluminum layer (i.e., a heating layer) and a paper or sheet layer (i.e., a structural layer). In other instances, a layer of another metal or metal alloy may be used to provide a heating layer for the first and / or second substrates 302, 304 in place of the aluminum layer.

[0032] Article 110 further includes a first aerosol generating material 306 deposited on a first substrate 302. Article 110 also includes a second aerosol generating material 308 deposited on a second substrate 304. Each of the first and second aerosol generating materials 306, 308 is an aerosol gel. The aerosol generating materials 306, 308 are deposited directly on the heating layer of the first substrate 302 and the second substrate 304. This means that the first substrate 302 and the second substrate 304 are arranged such that the heating layer is inside the article 110 and the structural layer is outside the heating layer and outside the article 110.

[0033] Article 110 is arranged such that the first aerosol generating material 306 and the second aerosol generating material 308 are positioned facing each other. Article 110 also includes at least one intermediate layer ( Figure 2 (Not shown in the image), which separates the first and second aerosol generating materials 306 and 308. See below for reference. Figures 4A to 4C At least one intermediate layer is described in more detail. In use, a heating layer, more specifically an aluminum foil, can be induced to generate heat, thereby heating the aerosol gel. The heating of the aerosol gel can generate an aerosol for use by a user, for example, through inhalation. The first and second aerosol generating materials 306, 308 at least partially define an airflow path therebetween. The aerosol generated by the first aerosol generating material 306 and the second aerosol generating material 308 can travel along the airflow path to the user. The article 110 includes a mouthpiece and a distal end opposite the mouthpiece. The mouthpiece is the end from which the user can use / inhale the aerosol. In some embodiments, the article may have a mouthpiece positioned at the mouthpiece. The mouthpiece may be made of a different material than the rest of the article. The mouthpiece may have a different construction than the rest of the article.

[0034] Article 110 is arranged such that the first aerosol generating material 306 and the second aerosol generating material 308 are separated by a gap d. During use, such as when a user inhales, the size of the gap d can affect the airflow velocity and / or pressure in the airflow path. The inventors have unexpectedly discovered that a particular value of the gap d results in the generation and / or delivery of more aerosol to the user. This may be because the airflow velocity and / or pressure in the airflow path affects the degree to which the aerosol generating material is heated (e.g., due to the cooling effect of the air) and / or the amount of aerosol carried by the airflow to the mouthpiece and / or the user.

[0035] Therefore, if the airflow velocity is not high enough, the airflow may carry insufficient aerosols, for example, depositing aerosol droplets before reaching the mouthpiece. If the gap d is too small, the flow velocity may be too high, which may cause the aerosol-generating material to be heated to a lower temperature, resulting in less aerosol generation.

[0036] In this embodiment, the gap d is greater than or equal to 0.9 mm. Advantageously, the inventors have found that d greater than or equal to 0.9 mm can mean an unexpectedly large increase in the mass of aerosol delivered to the user, for example, when compared with systems where d is less than 0.9 mm. More unexpectedly, it has been found that d greater than or equal to 1.34 mm further improves this effect. Even more unexpectedly, it has been found that d greater than 1.8 mm, such as substantially equal to 1.84 mm, can result in a larger mass of aerosol generated and / or delivered. As d increases beyond 1.84 mm, the mass of delivered aerosol can stabilize or decrease. In some embodiments, d can be less than or equal to 4 mm, for example, less than or equal to 2.5 mm, less than or equal to 2.34 mm, less than or equal to 2.2 mm, less than or equal to 2.1 mm, less than or equal to 2.0 mm, or less than or equal to 1.9 mm. When d decreases from 4 mm to 1.84 mm, more aerosol can be delivered to the user.

[0037] In this embodiment, the article is elongated. In other embodiments, the article is not elongated; for example, the article may be circular or square. In this embodiment, the article is substantially planar. In other embodiments, the article is not planar. In this embodiment, the first and / or second aerosol-generating material is an aerosol gel. In other embodiments, the first and / or second aerosol-generating material is not an aerosol gel, such as an aerosol solid or aerosol liquid. In this embodiment, the aerosol is generated by induction heating. In other embodiments, the aerosol is not generated by induction heating; heating occurs by another method, such as convection or conduction. In this embodiment, the substrate includes components that can be inductively excited to generate heat. In other embodiments, the substrate does not include components that can be inductively excited to generate heat; for example, the substrate may consist only of wood or paper. In this embodiment, the first substrate is the same as the second substrate. In other embodiments, the first substrate is different from the second substrate. In this embodiment, aluminum foil is arranged adjacent to the aerosol-generating material. In other embodiments, the aluminum foil is not arranged adjacent to the aerosol-generating material; for example, high-GSM paper is positioned between the aluminum foil and the aerosol-generating material. In this embodiment, the first and / or second substrates are made of high-GSM paper backed by aluminum foil. However, in other embodiments, the first and / or second substrates are not made of high-GSM paper backed by aluminum foil; for example, the first and / or second substrates may be made of copper foil or another material that can generate heat through induction. In this embodiment, the arrangement of the first substrate and the first aerosol-generating material is the same as that of the second substrate and the second aerosol-generating material. However, in other embodiments, the arrangement of the first substrate and the first aerosol-generating material differs from that of the second substrate and the second aerosol-generating material.

[0038] Reference Figure 3 The first substrate 302 has an elongated shape and extends in a longitudinal direction, from the mouth tip to the distal end. A first aerosol-generating material 306 is arranged in a series of discrete first portions 402-410 arranged sequentially in the longitudinal direction. The series of discrete first portions 402-410 are separated from and / or spaced apart from each other. Similarly, the second substrate 304 has an elongated shape extending in the longitudinal direction. A second aerosol-generating material 308 is arranged in a series of discrete second portions 412-420 arranged sequentially in the longitudinal direction. In use, the discrete portions of the aerosol-generating material are heated sequentially. For example, for each inhalation by the user, only one of these discrete portions is heated to generate an aerosol. However, in other embodiments, multiple discrete portions may be heated to generate an aerosol for each inhalation by the user.

[0039] In this embodiment, each discrete portion is shaped as a square. In other embodiments, each discrete portion is not shaped as a square; for example, each discrete portion is shaped as a circle or a rhombus. In this embodiment, the discrete portions are identical to each other. In other embodiments, the discrete portions are not identical to each other. In this embodiment, the discrete first portion is identical to the discrete second portion. In other embodiments, the discrete first portion is different from the discrete second portion; for example, the shape of the discrete second portion may be different from the shape of the discrete first portion. In this embodiment, the first and / or second aerosol generating material is arranged in a series of discrete portions. In other embodiments, the first and / or second aerosol generating material is not arranged in a series of discrete portions; for example, the first and / or second continuous aerosol generating material may be arranged in strips or continuous regular or continuous irregular shapes.

[0040] refer to Figure 4A Article 110 includes a first intermediate layer 502. The first intermediate layer 502 has an elongated, generally planar shape extending in a longitudinal direction. The first intermediate layer 502 is configured to be coupled to a first aerosol generating material 306. The first intermediate layer 502 includes a series of first holes. Each first hole has a shape complementary to a corresponding discrete first portion 402-410. The first intermediate layer 502 is configured to abut against the first aerosol generating material 306 and the first substrate 302, such that each of the discrete first portions 402-410 fits within its corresponding hole in the first intermediate layer 502.

[0041] In this embodiment, the first intermediate layer and the first aerosol-generating material extending therethrough can form a substantially planar surface. In this embodiment, the thickness of the first intermediate layer is substantially the same as the thickness of the first aerosol-generating material. In other embodiments, the first intermediate layer and the first aerosol-generating material do not form a substantially planar surface; for example, the first aerosol-generating material extends beyond the first intermediate layer. In this embodiment, the first intermediate layer includes a series of first holes. In other embodiments, the first intermediate layer does not include a series of first holes; for example, the first intermediate layer may include a single hole having a shape complementary to the shape of the first aerosol-generating material.

[0042] refer to Figure 4AThe article 110 also includes a second intermediate layer 504. The second intermediate layer 504 has a substantially planar shape extending in the longitudinal direction. The second intermediate layer 504 is configured to connect to the second aerosol generating material 308. The second intermediate layer 504 includes a series of second holes. Each of the series of second holes has a shape complementary to a corresponding discrete second portion 412-420. The second intermediate layer 504 is configured to abut the second aerosol generating material 308 such that each of the discrete second portions 412-420 is fitted into its corresponding second hole. In this way, the second intermediate layer 504 and the second aerosol generating material 308 extending through it can form a substantially planar surface. The thickness of the second intermediate layer 504 is substantially the same as the thickness of the second aerosol generating material 308.

[0043] In this embodiment, the second intermediate layer and the second aerosol-generating material can form a substantially planar surface. In this embodiment, the thickness of the second intermediate layer is substantially the same as the thickness of the second aerosol-generating material. In other embodiments, the second intermediate layer and the second aerosol-generating material do not form a planar surface; for example, the second aerosol-generating material extends beyond the second intermediate layer. In this embodiment, the second intermediate layer includes a series of second holes. In other embodiments, the second intermediate layer does not include a series of second holes; for example, the second intermediate layer may include a single hole having a shape complementary to the shape of the second aerosol-generating material.

[0044] refer to Figure 4A Article 110 also includes a third intermediate layer 506. The third intermediate layer 506 has a generally planar shape extending in the longitudinal direction. The third intermediate layer 506 includes an inlet opening 508 at a first end in the longitudinal direction. The pressure drop across article 110 can be important for the user experience. To increase the quality of aerosol delivered to the user (which is also important for the user experience), it has been found that avoiding blockage of aerosol-generating materials in the airflow path and increasing the outlet area can be beneficial. However, implementing these features may result in a pressure drop that is too small. Therefore, it may be beneficial to change the inlet area to control the pressure drop across article 110.

[0045] The third intermediate layer 506 also includes an outlet opening 510 at a second end of the third intermediate layer 506 along the longitudinal direction. The first end is opposite the second end along the longitudinal direction. The outlet opening 510 corresponds to the mouth end of the article 110. The user can inhale aerosols through the outlet opening 510. The applicant also unexpectedly discovered that the area of ​​the outlet opening 510 directly affects the quality of aerosols that may be generated and / or delivered to the user. When the outlet opening is smaller, the amount of aerosol generated tends to be smaller. Conversely, when the outlet opening is larger, the amount of aerosol generated also tends to be larger. Furthermore, increasing the area by increasing the width of the outlet opening rather than its thickness provides a more significant improvement in aerosol generation.

[0046] The third intermediate layer 506 also includes a conduit that fluidly connects the inlet opening 508 to the outlet opening 510. The inlet opening 508 allows air to enter the conduit. The third intermediate layer 506 is configured to provide a space and / or gap d between the first and second aerosol generating materials 306, 308. Therefore, the separation caused by the third intermediate layer 506 results in an airflow path between the first and second aerosol generating materials 306, 308. The conduit is positioned to at least partially cover the first and second aerosol generating materials 306, 308. The third intermediate layer 506 also includes a top surface configured to be coupled to and / or adjacent to the first intermediate layer 502. The third intermediate layer 506 also includes a bottom surface opposite the top surface. The bottom surface is configured to be coupled to and / or adjacent to the second intermediate layer 504. The direction extending from the top surface to the bottom surface is perpendicular to the longitudinal direction. The direction extending from the top surface to the bottom surface defines the thickness dimension. The thickness of the third intermediate layer 506 defines the dimension of the gap d. In other words, the thickness of the third intermediate layer 506 is the same as the distance d of the gap. In some embodiments, the dimension d of the gap is defined by the thickness of the third intermediate layer 506, in addition to the thickness of the adhesive layer used to adhere the third intermediate layer 506 to the first and second intermediate layers 502, 504. The third intermediate layer 506 includes a bridging member 512 extending across the width of the third intermediate layer 506. The width is defined in a direction perpendicular to both the longitudinal direction and the thickness direction. (See reference...) Figure 4BThe bridging element 512 has a thickness less than that of the third intermediate layer 506. Advantageously, this means that the bridging element tends not to obstruct airflow paths and / or ducts. In this embodiment, the bridging element is positioned adjacent to the bottom surface of the third intermediate layer. In other embodiments, the bridging element is not positioned near the bottom surface; for example, the bridging element may be positioned near the top surface of the third intermediate layer. In some embodiments, the bridging element may be positioned midway between the top and bottom surfaces of the third intermediate layer, i.e., the bridging element is positioned such that the distance between the bridging element and the top surface is the same as the distance between the bridging element and the bottom surface. In some embodiments, the bridging element may be offset relative to one or more lateral members on the first and / or second intermediate layers. The one or more lateral members can be considered as portions of the first and / or second intermediate layers that separate discrete portions of the aerosol-generating material. In some instances, the bridging element may be omitted to provide an airflow path (e.g., the third intermediate layer is provided as two separate elements).

[0047] refer to Figure 4C Article 110 also includes a flow control feature 514 positioned in the inlet opening 508. In this embodiment, the flow control feature 514 is a rib extending across the width of the inlet opening 508. The rib has a T-shape. The bottom of the T-shape contacts the second intermediate layer 504. The crossbar portion of the T-shape extends across the width of the inlet opening 508. The flow control feature 514 helps to direct air to a preferred area of ​​the airflow path, thereby increasing the aerosol mass carried by the airflow. Specifically, air entering the airflow path can be forced to flow around the flow control feature 514, thereby flowing closer to the first and / or second aerosol generating materials 306, 308. In this embodiment, the T-shape of the flow control feature 514 also forces the incoming air into the corner area of ​​the airflow path, thereby improving mixing.

[0048] Flow control feature 514 can also affect the velocity and / or pressure drop of air in the airflow path during user inhalation. Without this flow control feature, the velocity of the air entering the inlet when the user inhales can be much greater than the velocity of the stationary air within the airflow path. This can also reduce the mixing between the air entering through the inlet and the stationary air within the airflow path. This means that a central jet of air tends to form in such an article, which negatively impacts the performance of the article. Advantageously, the flow control feature tends to reduce and / or mitigate the formation of a central jet of air when the user inhales. Furthermore, the flow control feature tends to improve the mixing between the incoming air through the inlet and the stationary air within the airflow path.

[0049] Furthermore, flow control features can increase the pressure drop in the airflow path. Specifically, when a flow control feature is positioned within an inlet opening, it tends to reduce the area of ​​the inlet opening. As mentioned above, a smaller inlet opening tends to increase the pressure drop in the airflow path. In other words, when positioned within an inlet opening, the flow control feature can be considered to reduce the area of ​​the inlet opening.

[0050] In this embodiment, the flow control feature is positioned within the inlet opening. In this embodiment, the flow control feature has a T-shape. In other embodiments, the flow control feature does not have a T-shape; for example, the flow control feature has a cross-shaped, rod-shaped, or cuboid shape. In this embodiment, the flow control feature extends across the entire width of the inlet opening. In other embodiments, the flow control feature does not extend across the entire width of the inlet opening; for example, the flow control feature extends across a limited portion of the inlet opening.

[0051] In the above embodiments, the thickness of the third intermediate layer defines the size d of the gap. However, in other embodiments, the thickness of one or more of the first, second, and third intermediate layers defines the size d of the gap. In some embodiments, the gap is defined by the space between the first aerosol generating material and the second aerosol generating material. In some embodiments, the gap is defined by the space between the first substrate and the second substrate. In some embodiments, the gap is defined by one or more of the thickness of the first intermediate layer, the thickness of the second intermediate layer, the thickness of the third intermediate layer, the thickness of the first aerosol generating material, the thickness of the second aerosol generating material, the thickness of the first substrate, and the thickness of the second substrate. In the above embodiments, the article includes the first intermediate layer, the second intermediate layer, and the third intermediate layer. However, in other embodiments, the article does not include the first, second, and third intermediate layers. In some embodiments, the article includes one or more of the first, second, and third intermediate layers. In some embodiments, the inlet and / or outlet can be formed by folding or by passing a laser through one or more of these intermediate layers.

[0052] Various constructions have been tested, and these constructions support the remarkable advantages described in this specification. The results of the tests on these constructions show… Figure 5 , Figure 6A , Figure 6B , Figure 7A , Figure 7B and Figure 9The diagram shows the product used in the experiment, constructed from individual layers. These individual layers can be cut using a Silhouette, CNC, or laser cutter. These cut profiles can then be positioned and glued together. The assembled product can be tested in the lab using Borgwald equipment, repeated 5 or more times, for example, 10 times. Silhouette cutting is more reliable and has less variability compared to CNC.

[0053] Figure 5 The diagram shows materials with different gap dimensions d (where d is the spacing between the first aerosol generating material 306 and the second aerosol generating material 308, as shown in the reference above). Figure 2 A graph showing the relationship between the various experimental articles (described in article 110) and the amount (mass) of aerosol delivered by airflow to the mouthpiece of the user's inhalable aerosol. (See reference) Figure 5 Surprisingly, it was found that the amount of aerosol transported by the airflow increased when d = 1.34 mm. Furthermore, it can be seen that a further increase in the gap size d resulted in a further increase in the mass of aerosol transported. Figure 5 It can be seen that when d = 1.84 mm, more aerosols are transported, and as d increases beyond 1.84 mm, the amount of aerosols generated tends to stabilize.

[0054] Now for reference Figure 6A It shows the relationship between different inlet areas and pressure drop. The test was conducted to generate... Figure 6A and Figure 6B The product shown in the data has the same characteristics as Figure 8 The same structure as A1 in [the text] is described below. From Figure 6A The relationship diagram shows that the pressure drop increases as the inlet area decreases. This is especially true when the inlet area is less than 0.4 mm². 2 In articles with inlet openings, relatively large pressure drops have been found, which may adversely affect system performance and / or user experience. For example, this may prevent users from drawing and / or inhaling sufficient aerosol from the article. In some embodiments, the inlet opening may have a diameter greater than or equal to 0.15 mm. 2 The area, for example, greater than or equal to 0.2 mm. 2 ≥0.21 mm 2 ≥0.37 mm 2 ≥0.4 mm 2 ≥0.4 mm 2 ≥0.5 mm 2 ≥0.6 mm 2 ≥0.7mm 2 ≥0.8 mm2 , or greater than or equal to 0.86 mm 2 In some implementations, the inlet opening may include two holes.

[0055] Now refer to Figure 6B This graph illustrates the relationship between the amount (mass) of aerosol delivered and the inlet area of ​​different inlets with varying sizes for different products. It should be noted that the products tested against this graph are different from those used for... Figure 6A The products in the relationship diagram are the same. From Figure 6B The relationship diagram shows that 0.51 mm 2 The inlet area can provide the maximum amount of aerosol delivery. Furthermore, such as from... Figure 6B It can be seen that as the inlet area increases from 0.51 mm... 2 Reduced to 0.37 mm 2 The amount of aerosol transported also decreased. The applicant also unexpectedly discovered that below 0.5 mm... 2 The amount of aerosol transported is reduced from its maximum value. The applicant has also unexpectedly discovered that for particles larger than 5 mm... 2 For products with a larger inlet area, the amount of aerosol transported decreases from its maximum value. In some embodiments, the inlet opening may have a size of less than or equal to 5 mm. 2 The area, for example, less than or equal to 4 mm 2 Less than or equal to 3 mm 2 For example, less than or equal to 2.61 mm 2 Less than or equal to 1.91 mm 2 Less than or equal to 1.21mm 2 Less than or equal to 0.86 mm 2 .

[0056] Figure 7A A graph showing the relationship between different products with different outlet areas and the aerosol mass delivered per suction cycle is presented. Table 1 below lists... Figure 7A The parameters of different products are drawn in the image.

[0057]

[0058] Table 1

[0059] Figure 7A The structures of the different products shown are illustrated in Figure 8 In, among which: Sub 1 – 1 st The substrate, on which aerosol gels are deposited; Sub 2 – 2 nd The substrate, on which aerosol gels are deposited; 1 / 1a / 1b – First intermediate layer; 2 / 2a / 2b – Second intermediate layer; and 3 / 3a / 3b / 3c – Third intermediate layer.

[0060] In some articles, the first and second intermediate layers are each made of two separate planar components. In some articles, the third intermediate layer is made of three separate planar components. In some articles, the conduit tapers towards the inlet opening. In some articles, the conduit tapers towards the outlet opening. In some articles, the conduit tapers along this longitudinal direction from the outlet opening to the inlet opening. In these articles, the layer thickness is substantially constant. In these articles, the inlet area is constant.

[0061] from Figure 7A It can be seen that, compared to products with smaller outlet openings, products with larger outlet openings can convey a larger amount of aerosol. Specifically, compared to... Figure 7A Compared to other products, A2, A3, and A5 generate the largest amounts of aerosols. Furthermore, from... Figure 7A As can be seen, a larger outlet opening can increase the amount of aerosol delivered, regardless of different structural modifications to the article, such as varying degrees of tapering in the conduit. This is likely because a larger outlet opening reduces turbulence and / or mixing of the airflow leaving the airflow path. Thus, a larger outlet opening may tend to reduce the likelihood of aerosols separating from the airflow before delivery to the user. Furthermore, a certain amount of aerosol can be trapped at bends in the airflow path. A larger outlet opening may tend to reduce the size of these bends, thereby reducing the amount of aerosol that can be trapped in the airflow path.

[0062] For example, when with an area less than 2.55 mm 2 Compared to products with an export opening, the area is at least 2.55 mm. 2 The outlet opening tends to allow for the generation and / or delivery of a larger aerosol mass. Specifically, it has an approximate 6.85 mm... 2 The size of the outlet opening allows for a large amount of aerosol generated and / or delivered to the user. The outlet opening may be defined by the thickness of the third intermediate layer and the adhesive used to bond the third intermediate layer to the first and / or second intermediate layers. Alternatively or additionally, the outlet opening may be defined by the thickness of the first and / or second intermediate layers. In some embodiments, the outlet opening may have a size greater than or equal to 0.15 mm. 2 The area, for example, greater than or equal to 0.25 mm. 2 ≥0.5 mm 2 ≥0.75mm 2 ≥1.0 mm 2≥1.25 mm 2 ≥1.5 mm 2 ≥1.75 mm 2 ≥2.0 mm 2 ≥2.25 mm 2 ≥2.55 mm 2 ≥2.8 mm 2 ≥3 mm 2 ≥4 mm 2 ≥5 mm 2 , or greater than or equal to 7 mm 2 or greater than or equal to 9mm 2 , or greater than or equal to 10 mm 2 In some implementations, these outlet openings may have a diameter of less than or equal to 10 mm. 2 The area, for example, less than or equal to 9 mm 2 or less than or equal to 8 mm 2 or less than or equal to 7 mm 2 or less than or equal to 6mm 2 .

[0063] refer to Figure 7B , Figure 7B The graph shows the relationship between different products with increased export area and the amount of aerosol transported. Figure 7B Different products all have the same fixed entry area. From Figure 7B As can be seen from this, when the export area is increased to greater than 4.11 mm... 2 At that time, the amount of aerosol transported will not change significantly.

[0064] In this implementation method and in the above discussion, Figure 8In the experimental setup shown, the outlet and / or inlet openings of the articles tested are rectangular. Therefore, the area of ​​the outlet and / or inlet openings can be equal to the width w of the opening multiplied by the thickness of the third intermediate layer. The area of ​​the inlet and / or outlet can be based on the shape of the inlet and / or outlet. In some embodiments, the inlet and / or outlet opening is not rectangular; for example, the inlet and / or outlet can be circular. In some embodiments, the area of ​​the outlet and / or inlet opening is defined by the thickness of one or more intermediate layers. In some embodiments, the area of ​​the outlet and / or inlet opening is not defined by the thickness of one or more intermediate layers; for example, the inlet and / or outlet opening can be drilled, pierced, or laser-formed in the intermediate layer. Advantageously, drilling the inlet opening can help allow the inlet airflow to diffuse over the first and / or second aerosol-generating material. In some embodiments, multiple inlet openings are present at the distal end. In some embodiments, the inlet opening can have a thickness of approximately 0.88 mm. 2 Or 1.76 mm 2 The area. In some embodiments, setting the pressure drop in the range of 70-90 mmWG is particularly beneficial for user experience. In this embodiment, the inlet and / or outlet is formed in the third intermediate layer. In other embodiments, the inlet and / or outlet is not formed in the third intermediate layer; for example, the inlet and / or outlet may be formed on any one of the first intermediate layer, the second intermediate layer, the first substrate, and the second substrate. In this embodiment, the intermediate layer is separate from the first and / or second substrate. In other embodiments, the intermediate layer is not separate from the first and / or second substrate; for example, the intermediate layer may be integrally formed with the first and / or second substrate. In this embodiment, the third intermediate layer is integrally formed. In other embodiments, the third intermediate layer is not integrally formed; for example, the third intermediate layer may be formed from multiple separate components. In this embodiment, the third intermediate layer is planar. In other embodiments, the third intermediate layer is not planar. In this embodiment, the bridging element is positioned not to cover the first and second aerosol generating materials. In other embodiments, the bridging element is positioned to at least partially cover the first and / or second aerosol generating materials.

[0065] In some embodiments, the airflow path may be substantially unobstructed. Ensuring that the airflow path is as unobstructed as possible can benefit the performance of the article, for example, for achieving a specific pressure drop and / or a specific amount of aerosol delivered. An unobstructed airflow path may not have any structures located adjacent to the aerosol-generating material within the airflow path. In other words, there is nothing in the airflow path that can alter the trajectory of the air flowing near the aerosol-generating material. It should be noted that an unobstructed airflow path implementation may be consistent with an implementation containing a flow control feature positioned in the inlet and / or a bridging element included in a third intermediate layer. In other words, some implementations may have both an unobstructed airflow path and a flow control feature positioned in the inlet opening. The airflow path can be considered to be downstream of the inlet opening. Furthermore, including Figure 5 The intermediate layer of product A can also be considered unobstructed because there is no obstruction from aerosol-generating material. Specifically, since the bridging elements and / or flow control features are offset relative to and / or do not cover the aerosol-generating material, the flow of aerosols is not disturbed or altered by the bridging elements and / or flow control features.

[0066] Figure 9 A graph showing the relationship between different engineered products and the mass of the delivered aerosol, obtained from experimental tests, is presented. Different products may or may not include ribs in the airflow path. Table 2 below lists... Figure 9 The parameters of different products are drawn in the image.

[0067]

[0068] Table 2

[0069] Figure 9 The structures of the different products shown are illustrated in Figure 10 In, among which: Sub 1 – 1 st The substrate, on which aerosol gels are deposited; Sub 2 – 2 nd The substrate, on which aerosol gels are deposited; 1 / 1a / 1b – First intermediate layer; 2 / 2a / 2b – Second intermediate layer; and 3 / 3a / 3b / 3c – Third intermediate layer.

[0070] In some articles, the first and second intermediate layers are each made of two separate planar components. In some articles, the third intermediate layer is made of three separate planar components. In some articles, the conduit tapers toward the inlet opening. In some articles, the conduit tapers toward the outlet opening. In some articles, these conduits taper longitudinally from the outlet opening to the inlet opening. Figure 10 The ribs shown in Table 2 can be considered as transverse members that extend across the width of the intermediate layer and / or conduit as described above.

[0071] from Figure 9 It can be seen that articles without obstructions generally allow for a greater mass of delivered aerosol compared to articles with obstructions. Specifically, A9, A10, and A13 show that an unobstructed airflow path allows for the delivery of more aerosol compared to articles with ribs (A8, A11, and A12). This further demonstrates that the inlet region can provide a specific pressure drop without significantly affecting other performance factors. In these embodiments, the airflow path is substantially unobstructed. However, in other embodiments, the airflow path is unobstructed.

[0072] refer to Figure 11 When fully assembled, article 110 includes a first substrate 302 located on top of a first intermediate layer 502. A first aerosol-generating material 306, shown in dashed lines, extends from the bottom surface of the first substrate 302 into the first intermediate layer 502. In some embodiments, the first aerosol-generating material 306 may extend beyond the bottom surface of the first intermediate layer 502. The first intermediate layer 502 is positioned on top of a third intermediate layer 506. The third intermediate layer 506 is positioned on top of a second intermediate layer 504. The second intermediate layer 504 is positioned on top of a second substrate 304. A second aerosol-generating material 308, shown in dashed lines, extends from the top surface of the second substrate 304 into the second intermediate layer 504.

[0073] The first intermediate layer 502, the first aerosol generating material 306, the third intermediate layer 506, the second intermediate layer 504, and the second aerosol generating material 308 together form a channel that fluidly connects the inlet opening 508 to the outlet opening 510. The first intermediate layer 502, the first aerosol generating material 306, the second intermediate layer 504, and the second aerosol generating material 308 can be considered as a conduit surrounding the third intermediate layer 506, thereby forming the channel. The first aerosol generating material 306 and / or the second aerosol generating material 308 can be activated to generate aerosols in the channel and / or conduit. The channel and / or conduit can be considered as an airflow path.

[0074] In this embodiment, the channel is formed by a first intermediate layer, a first aerosol-generating material, a third intermediate layer, a second intermediate layer, and a second aerosol-generating material. In other embodiments, the cavity is not formed by the first intermediate layer, the first aerosol-generating material, the third intermediate layer, the second intermediate layer, and the second aerosol-generating material; for example, the channel may be formed by one or more of the first intermediate layer, the first aerosol-generating material, the third intermediate layer, the second intermediate layer, and the second aerosol-generating material.

[0075] The various embodiments described herein are provided only to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of implementations and are not exhaustive and / or exclusive. It should be understood that the advantages, implementations, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or on the equivalents of the claims, and other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. In addition to those specifically described herein, various embodiments of the invention may suitably include, consist of, or substantially consist of suitable combinations of the disclosed elements, components, features, parts, steps, devices, etc., or suitable combinations of the disclosed elements, components, features, parts, steps, devices, etc. Furthermore, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. An aerosol-forming article, comprising: The first surface contains a first aerosol-generating material; as well as A second surface, opposite to the first surface, defines an airflow path between the first surface and the second surface; The distance between the first aerosol generating material and the second surface is at most 4 mm.

2. The aerosol forming article according to claim 1, wherein the distance between the first aerosol generating material and the second aerosol generating material is at most 2.34 mm.

3. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at most 2.2 mm.

4. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at most 2.1 mm.

5. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at most 2.0 mm.

6. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at least 1.3 mm.

7. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at least 1.34 mm.

8. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at least 1.4 mm.

9. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at least 1.54 mm.

10. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at least 1.6 mm.

11. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at least 1.7 mm.

12. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is at least 1.84 mm.

13. The aerosol forming article according to any one of the preceding claims, wherein the distance between the first aerosol generating material and the second aerosol generating material is between 1.8 mm and 1.9 mm.

14. The aerosol forming article according to any one of the preceding claims, wherein the airflow path is unobstructed at the aerosol generating material between the first surface and the second surface.

15. The aerosol forming article according to any one of the preceding claims, wherein the first surface and / or the second surface is substantially planar.

16. The aerosol-forming article according to any one of the preceding claims further includes an outlet, said outlet allowing air to flow out of the article from between the first surface and the second surface, wherein said outlet has an area of ​​at least 1.75 mm². 2 and / or up to 5.5 mm 2 .

17. The aerosol forming article according to any one of the preceding claims, wherein the airflow path is unobstructed at the aerosol generating material between the first surface and the second surface.

18. The aerosol-forming article according to any one of the preceding claims, wherein: The second surface comprises a second aerosol-generating material; and The distance is defined between the first aerosol generating material and the second aerosol generating material.

19. An aerosol supply system, comprising: Aerosol-formed articles according to any one of the preceding claims; as well as An aerosol supply device is configured to heat the aerosol generating material to generate an aerosol.

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