Aerosol supply device

Abstract

An aerosol-forming article (110) comprising: a substantially planar first surface, the first surface comprising an aerosol-generating material (306); a substantially planar second surface opposite the first surface such that an airflow path is defined between the first surface and the second surface; and an outlet (510) configured to allow air to flow out of the airflow path, the outlet (510) having an area of at least 0.15 mm2.

Description

Technical Field

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

[0002] Smoking products such as cigarettes and cigars burn tobacco during use to produce tobacco smoke. Attempts have been made to create alternatives to these products that provide tobacco smoke by releasing compounds without combustion. Examples of such products include heating devices that release compounds by heating the material without burning it. The material can be, for example, tobacco or other non-tobacco products, which 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, substantially planar surface including an aerosol-generating material; a second, substantially planar surface opposite the first surface such that an airflow path is defined between the first and second surfaces; and an outlet configured to allow air to exit the airflow path. The outlet has a diameter of at least 0.15 mm. 2 The area.

[0004] The outlet can have a minimum diameter of 0.25 mm. 2 The area, for example, is at least 0.5 mm. 2 ≥0.75 mm 2 ≥1.0 mm 2 ≥1.25 mm 2 ≥1.5 mm 2 ≥1.75 mm 2 At least 2mm 2 The outlet can have a minimum diameter of 2.55 mm. 2 The area. The outlet can have at least 3 mm. 2 The area. The outlet can have at least 4.11 mm. 2 The area. The outlet can have at least 5 mm. 2 The area. The outlet can have approximately 6.85 mm. 2 or 7 mm 2 or 8 mm 2 or 9 mm 2 or 10 mm 2 or 11 mm 2 Or 12.33 mm 2The area of ​​the aerosol-forming article can be a layered structure. The layered structure can include a first layer defining a first surface and a second layer defining a second surface. The layered structure can be a folded layered structure. The layered structure can include an intermediate layer located between the first and second surfaces. An outlet can be formed in the intermediate layer. The layered structure can also include an additional intermediate layer between the first intermediate layer and the first layer. The layered structure can also include another additional intermediate layer between the intermediate layer and the second layer. The second surface comprises the aerosol-generating material. The area can be the cross-sectional area of ​​the outlet. The area can be the minimum cross-sectional area of ​​the outlet.

[0005] The airflow path may be unobstructed between the first and second surfaces of the aerosol-generating material. The first surface may include multiple discrete regions of the aerosol-generating material. These discrete regions may be displaced relative to each other in the longitudinal direction. The airflow path may be unobstructed between the first and second surfaces in each of the multiple discrete regions. The airflow path may be unobstructed over the entire area of ​​the aerosol-generating material between the first and second surfaces. The region of the airflow path between the first and second discrete regions may be unobstructed between the first and second surfaces.

[0006] In another aspect, an aerosol supply system is provided. This aerosol supply system includes any of the aforementioned aerosol forming articles and includes an aerosol supply device configured to heat the aerosol generating material to produce 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 is shown, taken in a plane parallel to the longitudinal axis of the article. 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 features; Figure 5 A graph showing the amount of aerosol delivered relative to the gap size is presented. Figure 6A A graph showing the pressure drop relative to multiple inlet areas is provided; Figure 6BA graph showing the amount of aerosol delivered relative to multiple inlet sizes is presented; Figure 7A A graph showing the amount of aerosol delivered for articles with different characteristics, where the different characteristics include different outlet areas; Figure 7B A graph showing the amount of aerosol delivered relative to multiple outlet areas is presented. Figure 8 The test results show the production Figure 7A The data shown is an exploded view of the structural components of each product. Figure 9 A graph showing the amount of aerosol delivered for articles with different characteristics 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 taken 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 a material capable of generating aerosols, for example, when heated, radiated, or electrified in any other way. Aerosol-generating materials may be in solid, liquid, or gel form, and may or may not contain active substances and / or flavorings. Aerosol-generating materials may 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 may be in solid, liquid, gel, wax, or other forms, for example. Aerosol-generating materials may also be, for example, combinations or mixtures of materials. Aerosol-generating materials may also be referred to as "inhalable materials."

[0009] The aerosol-generating material may include a binder and an aerosol-forming agent. Optionally, an activator and / or 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 or may not be soluble in the 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 be "amorphous solids". Amorphous solids can be "monolithic solids". In some embodiments, the amorphous solid may be a dried gel. Amorphous solids are solid materials that can retain some fluid (e.g., liquid) within them. In some embodiments, the aerosol-generating material may, for example, include from about 50 wt%, 60 wt%, or 70 wt% of amorphous solids 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 sheet materials, which may optionally be shredded to form shredded sheets. Aerosol-generating sheets or shredded sheets may be substantially tobacco-free.

[0012] According to this disclosure, a "non-flammable" aerosol supply system is a system in which the aerosol supply system (or its components) consists of aerosol generating materials that can deliver at least one substance to a user without burning or by burning.

[0013] In some implementations, the delivery system is a non-flammable aerosol supply system, such as a powered non-flammable aerosol supply system.

[0014] 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), although it is 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 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.

[0016] In some embodiments, the non-flammable aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to generate aerosols, one or more of which can be heated. Each of these aerosol-generating materials may 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-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables used in conjunction with the non-flammable aerosol supply device.

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

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

[0020] 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.

[0021] In some embodiments, consumables used with the non-flammable aerosol supply device may include aerosol generating material, aerosol generating material storage area, aerosol generating material delivery component, aerosol generator, aerosol generating area, housing, package, filter, nozzle and / or aerosol modifier.

[0022] Aerosol generating apparatus can receive articles containing aerosol-generating material for heating. As used herein, "article" refers to a component that includes or contains aerosol-generating material (which is heated to volatilize the aerosol-generating material) and optionally other components during use. A user may insert the article into the aerosol generating apparatus before heating it to generate an aerosol, after which the user inhales the aerosol. The article may, for example, have a predetermined or specific size configured to be placed within a heating chamber of the apparatus, the size of which is suitable for receiving the article.

[0023] See 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 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 inhaled by a user of the device 100. In this embodiment, the aerosol forming article 110 is used in conjunction with the aerosol supply device 100. However, in other embodiments, 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 to surround and accommodate a plurality of components of the body 102. An article orifice 104 is formed at one end of the body 102, through which an article 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 that 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 is positioned along a longitudinal axis aligned with the axis of the product 110.

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

[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 aperture 104, such that an aerosol is generated from the aerosol-generating material. The power source supplies electrical energy 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. Suitable battery embodiments 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 power for heating 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 via pressing a button or opening a door of the device (e.g., a door covering the consumable receiving compartment). 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 for heating aerosol-generating materials via an induction heating process. Induction heating is a process of heating a conductive heating element (e.g., 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 (e.g., alternating current) through the sensing element. The changing current in the sensing element generates a changing magnetic field. The changing magnetic field passes through a 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 heats the sensor by Joule heating. In cases where the sensor comprises a ferromagnetic material such as iron, nickel, or cobalt, heat may also be generated by hysteresis losses in the sensor, i.e., by the changing orientation of magnetic dipoles in the magnetic material due to their alignment with the changing magnetic field. In induction heating, heat is generated within the sensor compared to heating by, for example, conduction, allowing for rapid heating. Furthermore, no physical contact is required between the sensing element and the sensor, allowing for increased freedom in construction and application.

[0031] refer to Figure 2 Article 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-grammage (g / m³, GSM) paper, such as 70 gsm to 400 gsm or 100 gsm to 400 gsm paper, such as 240 gsm paper, or any paper with 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 substrate 302 and the second substrate 304 can be considered as a double-layer laminate, such as a card or paper backed with a metal surface. In other words, both the first substrate 302 and / or the second substrate 304 comprise an aluminum layer (i.e., a heating layer) and a paper or sheet layer (i.e., a structural layer). In other embodiments, a layer of another metal or metal alloy may be used to provide a heating layer for the first substrate 302 and / or the second substrate 304 instead of the aluminum layer.

[0032] Article 110 also 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 aerosol generating material 306 and the second aerosol generating material 308 is an aerosol gel. The aerosol generating materials 306 and 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 outward relative to the heating layer, on the outside of the article 110.

[0033] The article 110 is arranged such that the first aerosol generating material 306 and the second aerosol generating material 308 are positioned facing each other. The article 110 also includes at least one intermediate layer separating the first aerosol generating material 306 and the second aerosol generating material 308. Figure 2 (Not shown in the image). The following text is about... Figures 4A to 4C At least one intermediate layer will be explained in more detail. In use, a heating layer, more specifically an aluminum foil, may generate heat, for example via induction heating, to heat the aerosol gel. Heating the aerosol gel produces an aerosol that can be used by a user (e.g., by inhalation). A first aerosol-generating material 306 and a second aerosol-generating material 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. 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 inhaled by a user, 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 materials are 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 they reach the nozzle tip. If the gap d is too small, the flow rate may be too high, which may cause the aerosol-generating material to be heated to a lower temperature, resulting in less aerosol production.

[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 to a system with d 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 produce and / or deliver a larger mass of aerosol. As d increases beyond 1.84 mm, the mass of aerosol delivered may 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 have a circular or square shape. In this embodiment, the article is substantially planar. In other embodiments, the article is not planar. In this embodiment, the first aerosol-generating material and / or the second aerosol-generating material is an aerosol gel. In other embodiments, the first aerosol-generating material and / or the 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, and heating occurs by another method, such as by convection or conduction. In this embodiment, the substrate includes components that can generate heat via induction heating. In other embodiments, the substrate does not include components that can generate heat via induction heating; for example, the substrate may only contain 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 substrate and / or the second substrate is made of high-GSM paper backed by aluminum foil. However, in other embodiments, the first substrate and / or the second substrate is not made of high-GSM paper backed by aluminum foil; for example, the first substrate and / or the second substrate 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 the arrangement of the second substrate and the second aerosol-generating material. However, in other embodiments, the first substrate and the first aerosol-generating material are arranged in a manner different from the arrangement of the second substrate and the second aerosol-generating material.

[0038] See 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 disposed within a series of discrete first portions 402-410 arranged sequentially in the longitudinal direction. These 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 disposed within 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 of the discrete portions is not shaped as a square; for example, each of the discrete portions 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 discrete second portion may have a shape different from that of the discrete first portion. In this embodiment, the first aerosol generating material and / or the second aerosol generating material are arranged in a series of discrete portions. In other embodiments, the first aerosol generating material and / or the second aerosol generating material are not arranged in a series of discrete portions; for example, the first continuous aerosol generating material and / or the 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 the first aerosol generating material 306 and the first substrate 302, such that each of the discrete first portions 402-410 is fitted into its corresponding hole in the first intermediate layer 502.

[0041] In this embodiment, the first intermediate layer and the first aerosol-generating material extending through the first intermediate layer 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 within its corresponding second hole. Thus, the second intermediate layer 504 and the second aerosol generating material 308 extending through the second intermediate layer 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 blockages in the airflow path near the aerosol generating material 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 vary 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 nozzle end of the article 110. The user can inhale aerosols through the outlet opening 510. The applicant has 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 tends to provide 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 aerosol generating material 306 and the second aerosol generating material 308. Thus, the space created by the third intermediate layer 506 forms an airflow path between the first aerosol generating material 306 and the second aerosol generating material 308. The conduit is positioned to at least partially cover the first aerosol generating material 306 and the second aerosol generating material 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 gap distance d. In some embodiments, the size of the gap d is defined by the thickness of the third intermediate layer 506 plus 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 portion 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 also Figure 4BThe thickness of the bridging portion 512 is less than the thickness of the third intermediate layer 506. Advantageously, this means that the bridging portion tends not to obstruct airflow paths and / or ducts. In this embodiment, the bridging portion is positioned adjacent to the bottom surface of the third intermediate layer. In other embodiments, the bridging portion is not positioned near the bottom surface; for example, the bridging portion may be positioned near the top surface of the third intermediate layer. In some embodiments, the bridging portion may be positioned midway between the top and bottom surfaces of the third intermediate layer, i.e., the bridging portion is positioned such that the distance between the bridging portion and the top surface is the same as the distance between the bridging portion and the bottom surface. In some embodiments, the bridging portion may be displaced relative to one or more lateral members on the first and / or second intermediate layers. These one or more lateral members can be considered as portions of the first and / or second intermediate layers that separate discrete portions of these aerosol-generating materials. In some embodiments, the bridging portion may be omitted to provide airflow paths (e.g., the third intermediate layer is provided as two separate components).

[0047] refer to Figure 4C The 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 entire width of the inlet opening 508. The flow control feature 514 helps guide air to a preferred area of ​​the airflow path, thereby increasing the mass of aerosol carried by the airflow. Specifically, air entering the airflow path can be directed to flow around the flow control feature 514, thus flowing closer to the first aerosol generating material 306 and / or the second aerosol generating material 308. In this embodiment, the T-shape of the flow control feature 514 also directs incoming air into the corner regions of the airflow path, thereby improving mixing.

[0048] The flow control feature 514 can also affect the velocity and / or pressure drop of the air in the airflow path during user inhalation. Without this flow control feature, the velocity of the air entering the inlet when a user inhales may be much greater than that of the stationary air in the airflow path. This could also reduce the mixing between the air entering through the inlet and the stationary air in the airflow path. This means that the central jet of air tends to be formed by a component that negatively impacts its performance. Advantageously, the flow control feature tends to reduce and / or mitigate the central air jet formed when a user inhales. Furthermore, the flow control feature tends to improve the mixing between the incoming air through the inlet and the stationary air in the airflow path.

[0049] Furthermore, the flow control feature can increase the pressure drop in the airflow path. Specifically, when the flow control feature is positioned within the inlet opening, it tends to reduce the area of ​​the inlet opening. As discussed above, a smaller inlet opening tends to increase the pressure drop in the airflow path. In other words, when positioned within the 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, it may have 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, it may extend across a limited portion of the inlet opening.

[0051] In the above embodiments, the thickness of the third intermediate layer defines the size of the gap d. However, in other embodiments, the thickness of one or more of the first, second, and third intermediate layers defines the size of the gap d. In some embodiments, the gap is defined by the space between the first and second aerosol-generating materials. In some embodiments, the gap is defined by the space between the first and second substrates. In some embodiments, the gap is defined by one or more of the thicknesses of the first, second, and third intermediate layers, the first and second aerosol-generating materials, the first and second substrates. In the above embodiments, the article includes the first, second, and third intermediate layers. 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 structural articles have been tested, and the articles support the surprising advantages described in this specification. Results from the article tests 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. Each layer can be cut using a Silhouette cutting machine, CNC machine, or laser cutter. These cut profiles can then be positioned and glued together. The assembled product can be tested in the laboratory using Borgwald equipment, repeated 5 times or more, for example, 10 times. For example, compared to CNC, Silhouette cutting tends to be more reliable and has less variability.

[0053] Figure 5 The diagram shows dimensions with different gaps d (where d is the spacing between the first aerosol generating material 306 and the second aerosol generating material 308, as referenced above). Figure 2 A graph showing the amount (mass) of aerosol delivered by airflow to the mouthpiece of the user for inhalation, based on multiple experimental articles (described in article 110). See also Figure 5 Surprisingly, it was found that when d = 1.34 mm, the amount of aerosol transported by the airflow increased. Furthermore, it can be seen that a further increase in the gap size d leads to a further increase in the mass of aerosol transported. From... Figure 5 It can be seen that when d=1.84 mm, the most aerosols are transported. As d increases beyond 1.84 mm, the amount of aerosols produced reaches a plateau.

[0054] See now Figure 6A It displays a graph showing the pressure drop relative to multiple inlet areas. Tests were conducted to produce... 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 graph 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 could result in the user not being able to draw and / or inhale 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 ≥0.7 mm 2≥0.8 mm 2 , 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 It shows a graph depicting the amount (mass) of delivered aerosol relative to the multiple inlet areas of an article with multiple inlets of different areas. It should be noted that the articles tested against this graph are different from those used for... Figure 6A The charts are identical to those of the products. From Figure 6B As can be seen from the chart, 0.51 mm 2 The inlet area can maximize the amount of aerosol transported. Furthermore, if from... Figure 6B As can be seen, with the entrance area increasing 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 delivered decreases from its maximum value. The applicant has also unexpectedly discovered that for particles larger than 5 mm... 2 For articles with a larger inlet area, the amount of aerosol delivered 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 1.91mm 2 Less than or equal to 1.21 mm 2 Less than or equal to 0.86 mm 2 .

[0056] Figure 7A A graph showing the mass of aerosol delivered per suction cycle is presented, plotted relative to multiple articles with different outlet areas. Table 1 below lists... Figure 7A The parameters of multiple products are drawn in the image.

[0057]

[0058] Table 1

[0059] Figure 7A The structures of the various products shown are as follows Figure 8 As shown, where: Sub 1 – First substrate, having an aerosol gel deposited thereon; Sub 2 – Second substrate, with aerosol gel deposited thereon; 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 longitudinally from the outlet opening to the inlet opening. In some articles, the layer thickness is substantially constant. In these articles, the inlet area is constant.

[0061] from Figure 7A As can be seen, when compared to products with smaller outlet openings, products with larger outlet openings can convey a larger mass of aerosol. Specifically, compared to... Figure 7A Compared to other products, A2, A3, and A5 produce the largest amounts of aerosols. Furthermore, from... Figure 7A As can be seen, a larger outlet opening can increase the amount of aerosol delivered, despite different structural modifications to the product, 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, bends in the airflow path can trap a certain amount of aerosol. A larger outlet opening tends 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 a diameter less than 2.55 mm 2 Compared to the area of ​​the outlet opening of the product, it has at least 2.55 mm. 2 The area of ​​the outlet opening tends to enable the generation and / or transport of a larger mass of aerosol. Specifically, it has an area of ​​approximately 6.85 mm. 2 The outlet opening of a certain area can generate a particularly large amount of aerosol and / or deliver a large quantity of aerosol to the user. The outlet opening may be defined by the thickness of the third intermediate layer and the thickness of 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 thickness greater than or equal to 0.15 mm. 2 The area, for example, greater than or equal to 0.25 mm². 2 ≥0.5 mm 2 ≥0.75 mm 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 ≥2.55mm 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 9 mm 2 , or greater than or equal to 10 mm 2 In some embodiments, the outlet opening 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 7mm 2 or less than or equal to 6 mm 2 or less than or equal to 5 mm 2 or less than or equal to 4.11 mm 2 .

[0063] refer to Figure 7B It shows a graph depicting the amount of aerosol delivered relative to multiple products with increased outlet area. Figure 7B Multiple products all have the same fixed inlet area. From Figure 7B As can be seen from this, when the export area is increased to greater than 4.11 mm... 2 Afterwards, the amount of aerosol transported did not change significantly.

[0064] In this embodiment, and as discussed above, 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 formed in the intermediate layer by drilling, piercing, or laser processing. Advantageously, drilling of the inlet opening can help diffuse the inlet airflow over the first and / or second aerosol generating materials. In some embodiments, multiple inlet openings are present at the distal end. In some embodiments, the inlet opening can have approximately 0.88 mm. 2 or 1.76 mm 2 The area. In some embodiments, a pressure drop of 70-90 mmWG (millimeters of water column) is particularly beneficial for user experience. In this embodiment, the inlet and / or outlet are formed in the third intermediate layer. In other embodiments, the inlet and / or outlet are 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 substrate and / or the second substrate. In other embodiments, the intermediate layer is not separate from the first substrate and / or the second substrate; for example, the intermediate layer may be integrally formed with the first substrate and / or the 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 portion is positioned not to cover the first aerosol generating material and the second aerosol generating material. In other embodiments, the bridging portion is positioned to at least partially cover the first aerosol generating material and / or the second aerosol generating material.

[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 mass of the aerosol for delivery. An unobstructed airflow path may not have any structures located adjacent to the aerosol-generating material within the airflow path. In other words, nothing in the airflow path alters the trajectory of the air flowing near the aerosol-generating material. It should be noted that embodiments with an unobstructed airflow path may be consistent with embodiments having a flow control feature positioned in the inlet and / or including a bridging portion in a third intermediate layer. In other words, some embodiments 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 free of obstructions because there are no obstructions from the aerosol-generating material. Specifically, since the bridging portion and / or flow control feature are displaced from and / or do not cover the aerosol-generating material, the flow of the aerosol is not disturbed or altered by the bridging portion and / or flow control feature.

[0066] Figure 9 A graph showing the delivered aerosol mass relative to various products obtained from experimental testing of engineered artifacts is presented. The various artifacts may or may not have ribs in the airflow path. Table 2 provided below lists... Figure 9 The parameters of various products are drawn in the image.

[0067]

[0068] Table 2

[0069] Figure 9 The structures of the various articles shown are illustrated in Figure 10 In, among which: Sub 1 – First substrate, having an aerosol gel deposited thereon; Sub 2 – Second substrate, with aerosol gel deposited thereon; 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 towards the inlet opening. In some articles, the conduit tapers towards the outlet opening. In some articles, the conduit tapers longitudinally from the outlet opening to the inlet opening. Figure 10The ribs shown in Table 2 can be considered as one or more of the aforementioned transverse members extending across the width of the intermediate layer and / or conduit.

[0071] As from Figure 9 It is evident 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 area can provide for customization of 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 obstructed.

[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 the 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 channel 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 embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or on 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: A substantially planar first surface, the first surface comprising an aerosol-generating material; A substantially planar second surface, which is opposite to the first surface, such that an airflow path is defined between the first surface and the second surface; as well as An outlet, configured to allow air to flow out of the airflow path; The outlet has a diameter of at least 0.15 mm. 2 The area.

2. The aerosol-forming article according to claim 1, wherein, The outlet has a diameter of at least 2.55 mm. 2 The area.

3. The aerosol-forming article according to any one of the preceding claims, wherein, The outlet has at least 3 mm 2 The area.

4. The aerosol-forming article according to any one of the preceding claims, wherein, The outlet has a diameter of at least 4.11 mm. 2 The area.

5. The aerosol-forming article according to any one of the preceding claims, wherein, The outlet has at least 5 mm 2 The area.

6. The aerosol-forming article according to any one of the preceding claims, wherein, The outlet has a diameter of approximately 6.85 mm. 2 The area.

7. The aerosol-forming article according to any one of the preceding claims, wherein, The aerosol-forming article is composed of a layered structure, the layered structure including a first layer defining the first surface and a second layer defining the second surface.

8. The aerosol-forming article according to claim 7, wherein, The layered structure is a folded layered structure.

9. The aerosol-forming article according to claim 7 or claim 8, wherein, The layered structure includes an intermediate layer located between the first surface and the second surface, wherein the outlet is formed in the intermediate layer.

10. The aerosol-forming article according to claim 9, wherein, The layered structure also includes an additional intermediate layer located between the first intermediate layer and the first layer.

11. The aerosol-forming article according to claim 9 or claim 10, wherein, The layered structure also includes an additional intermediate layer located between the intermediate layer and the second layer.

12. The aerosol-forming article according to any one of the preceding claims, wherein, The second surface includes an aerosol-generating material.

13. The aerosol-forming article according to any one of claims 1 to 12, wherein, The airflow path located between the first surface and the second surface is unobstructed at the aerosol generating material.

14. The aerosol-forming article according to claim 13, wherein, The first surface includes multiple discrete regions of the aerosol-generating material.

15. The aerosol-forming article according to claim 13 or 14, wherein, The plurality of discrete regions are shifted relative to each other in the longitudinal direction.

16. The aerosol-forming article according to any one of claims 13 to 15, wherein, The airflow path located between the first surface and the second surface is free of obstructions at each of the plurality of discrete regions.

17. The aerosol-forming article according to any one of claims 13 to 16, wherein, The airflow path located between the first and second surfaces traverses the entire area of ​​the aerosol-generating material without obstructions.

18. The aerosol-forming article according to any one of claims 13 to 17, wherein, The airflow path located between the first surface and the second surface is free of obstructions in the region between the first discrete region and the second discrete region.

19. An aerosol supply system, comprising: Aerosol-formed article 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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