Aerosol supply device

Abstract

An aerosol supply device comprises a magnetic field generator (300) comprising a plurality of flexible substrates (301a, 301b, 301c), where each substrate (301a, 301b, 301c) comprises one or more electrically conductive elements, where the plurality of substrates (301a, 301b, 301c) are deformed to form a substantially tubular element.

Description

Technical Field

[0001] This invention relates to an aerosol supply device, an aerosol supply system, a method for manufacturing a magnetic field generator or an aerosol supply device, and a method for generating aerosols. Background Technology

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

[0003] Aerosol supply systems covering the aforementioned devices or products are known. Typical systems use a heater to generate an aerosol from a suitable medium, which is then inhaled by the user.

[0004] It is known that induction heaters in the form of helical induction coils are used to heat the medium.

[0005] Traditional aerosol supply devices consist of a cylindrical heated chamber surrounded by a helical induction coil, into which a rod-shaped consumable is inserted. The size of the device is typically determined by the diameter of the helical induction coil. Summary of the Invention

[0006] According to one aspect, an aerosol supply device is provided, the aerosol supply device comprising: A magnetic field generator includes multiple flexible substrates, each substrate including one or more conductive elements, wherein the multiple substrates are deformed to form a substantially tubular element.

[0007] Optionally, the tubular element essentially comprises one or more helical conductive elements.

[0008] According to one aspect, an aerosol supply device is provided, the aerosol supply device comprising: A magnetic field generator includes a flexible substrate, wherein the substrate includes one or more conductive elements, and wherein the substrate itself overlaps to form a substantially tubular element.

[0009] Optionally, one or more conductive elements include: multiple electrically conductive tracks arranged to form a plurality of substantially parallel electrical paths.

[0010] Optionally, the substrate or each substrate may contain an electrical insulator.

[0011] Optionally, the substrate or each substrate may contain a polymer or plastic.

[0012] Optionally, the substrate or each substrate contains polyimide.

[0013] Optionally, the thickness of the substrate or each substrate is: (i) < 10 µm; (ii) 10–20 µm; (iii) 20–30 µm; (iv) 30–40 µm; (v) 40–50 µm; (vi) 50–60 µm; (vii) 60–70 µm; (viii) 70–80 µm; (ix) 80–90 µm; (x) 90–100 µm; (xi) 100–200 µm; (xii) 200–300 µm; (xiii) 300–400 µm; (xiv) 400–500 µm; (xv) 500–600 µm; (xvi) 600–700 µm; (xvii) 700–800 µm. µm; (xviii)800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii)4-5 mm; or (xxiv) > 5 mm.

[0014] Optionally, one or more conductive elements comprise a metal or a metal alloy.

[0015] Optionally, one or more conductive elements comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, brass, bronze, or zinc.

[0016] Optionally, the aerosol supply device may further include a magnetic shielding element.

[0017] Optionally, the magnetic shielding elements are arranged to surround at least a portion of the magnetic field generator.

[0018] Optionally, the magnetic shielding element comprises a ferromagnetic material.

[0019] Optionally, the ferromagnetic material comprises one or more of the following: (i) iron; (ii) nickel; and (iii) cobalt.

[0020] Optionally, the aerosol supply device may further include heat insulation components.

[0021] Optionally, the thermal insulation component is surrounded by at least a portion of the magnetic field generator.

[0022] Optionally, the insulation component may be made of ceramic or plastic.

[0023] Optionally, the thickness of the one or more conductive elements is: (i) < 10 µm; (ii) 10-20 µm; (iii) 20-30 µm; (iv) 30-40 µm; (v) 40-50 µm; (vi) 50-60 µm; (vii) 60-70 µm; (viii) 70-80 µm; (ix) 80-90 µm; (x) 90-100 µm; (xi) 100-200 µm; (xii) 200-300 µm; (xiii) 300-400 µm; (xiv) 400-500 µm; (xv) 500-600 µm; (xvi) 600-700 µm; (xvii) 700-800 µm; (xviii) 800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii) 4-5 mm; or (xxiv) > 5 mm.

[0024] Optionally, the width of the one or more conductive elements is: (i) < 10 µm; (ii) 10-20 µm; (iii) 20-30 µm; (iv) 30-40 µm; (v) 40-50 µm; (vi) 50-60 µm; (vii) 60-70 µm; (viii) 70-80 µm; (ix) 80-90 µm; (x) 90-100 µm; (xi) 100-200 µm; (xii) 200-300 µm; (xiii) 300-400 µm; (xiv) 400-500 µm; (xv) 500-600 µm; (xvi) 600-700 µm; (xvii) 700-800 µm; (xviii) 800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii) 4-5 mm; or (xxiv) > 5 mm.

[0025] According to one aspect, an aerosol supply system is provided, the aerosol supply system comprising: The aerosol supply device as described above; and Aerosol-generating products, including aerosol-generating materials.

[0026] According to one aspect, a method for manufacturing a magnetic field generator for an aerosol supply device is provided, the method comprising: Provides a plurality of flexible substrates, wherein each substrate includes one or more conductive elements; and The multiple substrates are deformed to form a substantially tubular element.

[0027] According to one aspect, a method for manufacturing a magnetic field generator for an aerosol supply device is provided, the method comprising: A flexible substrate is provided, wherein the substrate includes one or more conductive elements; and The substrate is deformed such that it overlaps itself to form a substantially tubular element.

[0028] Optionally, the method further includes depositing, sputtering, laser-activated, implanting, etching, or printing one or more conductive elements on or onto one or more substrates.

[0029] According to one aspect, a method for generating aerosols is provided, the method comprising: An aerosol supply device is provided, the aerosol supply device including a magnetic field generator, the magnetic field generator including a plurality of flexible substrates, wherein each substrate includes one or more conductive elements, wherein the plurality of substrates are deformed to form a substantially tubular element. Inserting an aerosol-generating article containing aerosol-generating materials into an aerosol supply device; and Start the aerosol supply device.

[0030] According to one aspect, a method for generating aerosols is provided, the method comprising: An aerosol supply device is provided, the aerosol supply device including a magnetic field generator, the magnetic field generator including a flexible substrate, wherein the substrate includes one or more conductive elements, wherein the substrate itself overlaps to form a substantially tubular element. Inserting an aerosol-generating article containing aerosol-generating materials into an aerosol supply device; and Start the aerosol supply device. Attached Figure Description

[0031] The various embodiments will now be described by way of example only and with reference to the accompanying drawings, wherein: Figure 1 A is a schematic diagram of a known heating assembly of an aerosol supply device, which includes a single induction coil formed by a wire wound around a tubular support, and shows an aerosol-generating article partially inserted into the tubular support. Figure 1 B shows Figure 1 A shows a cross-section of the heating assembly, and also shows a tubular sensor located within a tubular support and an aerosol-generating article partially inserted into the tubular sensor; Figure 2One embodiment is shown in which one or more copper tracks are deposited on or otherwise disposed on a substrate (which may include, for example, a polyimide sheet), and wherein the substrate is deformed into a tubular form, and wherein positive and negative electrical connections are then attached to the substrate which is now in a tubular form. Figure 3 One embodiment is shown in which the magnetic field generator is formed from a plurality of flexible substrates (e.g., three substrates), each substrate including one or more conductive elements, and wherein the plurality of substrates are stacked on top of each other and deformed to form a substantially tubular element. Figure 4 A cross-sectional view of one embodiment is shown, wherein the magnetic field generator is formed of a plurality of flexible substrates (e.g., three flexible substrates), wherein each substrate includes one or more conductive elements, and wherein thermal insulation elements or layers are disposed radially inside the flexible substrates, and wherein magnetic shielding elements are formed around the substrates. Figure 5 One embodiment is shown in which, for example, copper tracks are formed on a substrate (such as a polyimide sheet), and the substrate is then rolled up or wound to form a roll, such that the substrate overlaps itself. Figure 6 A method for manufacturing a magnetic field generator according to one embodiment is shown; and Figure 7 A method for manufacturing a magnetic field generator according to one embodiment is shown. Detailed Implementation

[0032] This document discusses or describes aspects and features of certain examples and implementations. Some aspects and features of certain examples and implementations can be conventionally implemented, and for the sake of brevity, these aspects and features are not discussed or described in detail. Therefore, it should be understood that aspects and features of the devices and methods discussed herein that are not described in detail can be implemented based on conventional techniques used to implement such aspects and features.

[0033] According to this disclosure, a "non-combustible" aerosol supply system is a system in which the constituent aerosol generating materials (or components thereof) of the aerosol supply system do not ignite or burn in order to facilitate the delivery of at least one substance to a user.

[0034] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system. In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also known as an evaporation device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol generating material is not necessary.

[0035] 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.

[0036] 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 aerosol-generating material 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.

[0037] Typically, a non-combustible aerosol supply system may include a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0038] In some embodiments, this disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-combustible aerosol supply devices. In this disclosure, these consumables are sometimes referred to as articles.

[0039] In some embodiments, a non-combustible aerosol supply system (such as a non-combustible aerosol supply device) may include a power source and a controller. The power source may be, for example, an electrical power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon substrate that can be powered to distribute power as heat to aerosol-generating or heat-transferring material adjacent to the exothermic power source.

[0040] 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, nozzles, filters, and / or aerosol modifiers.

[0041] In some embodiments, consumables for use with non-combustible aerosol supply devices may include aerosol generating material, aerosol generating material storage area, aerosol generating material transfer component, aerosol generator, aerosol generating area, housing, packaging, filter, nozzle and / or aerosol modifier.

[0042] Aerosol-generating materials are materials that can generate aerosols, for example, when heated, irradiated, or otherwise powered. Aerosol-generating materials can be in the form of, for example, solid, liquid, or semi-solid (such as gel), and may or may not contain active substances and / or flavorings.

[0043] The aerosol-generating material may comprise a binder and an aerosol-forming agent. Optionally, activators and / or fillers may also be present. Optionally, a solvent such as water is also present, and one or more other components of the aerosol-generating material may be soluble or insoluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0044] Aerosol-generating materials may include one or more active substances and / or flavoring agents, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0045] An aerosol generator is a device configured to generate aerosols from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy in order to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate aerosols from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0046] Consumables are articles containing or composed of aerosol-generating materials, which are intended in whole or in part for consumption by a user during use. Consumables may include one or more other components, such as aerosol-generating material storage areas, aerosol-generating material transfer components, aerosol-generating areas, housings, packaging, nozzles, filters, and / or aerosol modifiers. Consumables may also include aerosol generators, such as heaters, which generate heat during use to cause the aerosol-generating materials to generate aerosols. Heaters may include, for example, combustible materials, materials that can be heated electrically, or sensors.

[0047] Non-combustible aerosol supply systems may include modular components comprising a reusable aerosol supply device and a replaceable aerosol generating article. In some embodiments, the non-combustible aerosol supply device may include a power source and a controller (or control circuitry). The power source may include, for example, an electrical power source, such as a battery or a rechargeable battery. In some embodiments, the non-combustible aerosol supply device may also include an aerosol generating component. However, in other embodiments, the aerosol generating article may partially or wholly comprise the aerosol generating component.

[0048] For completeness, aerosol supply devices including sensing elements are known. An aerosol supply device may include one or more sensors and a sensor arranged to be heated by the one or more sensors.

[0049] A sensor is a material that can be heated by penetrating a changing magnetic field, such as an alternating magnetic field. The sensor can be a conductive material, such that penetrating the sensor with a changing magnetic field induces inductive heating of the heating material. The heating material can be a magnetic material, such that penetrating the heating material with a changing magnetic field induces hysteresis heating of the heating material. The sensor can be both conductive and magnetic, allowing it to be heated by both heating mechanisms. An aerosol supply device configured to generate a changing magnetic field is referred to herein as a magnetic field generator.

[0050] Figure 1 A shows a conventional induction heating assembly 100 for an aerosol supply device, and Figure 1 B shows Figure 1 A cross-section of the induction heating assembly 100 of the aerosol supply device shown in Figure A. The heating assembly 100 includes a tubular support on which a helical induction coil 112 made of wire is formed. The heating assembly 100 has a first proximal or distal end 102 and a second distal end 104. An aerosol generating article 130 is shown inserted into the tubular support. Figure 1 As shown in Figure B, the tubular receptor 140 is located within the tubular support, and the aerosol generating article 130 is shown as being partially located within the tubular receptor 140.

[0051] In use, an AC current passes through the spiral induction coil 112, which generates a changing magnetic field. This changing magnetic field induces eddy currents within the sensor 140, thereby rapidly heating the sensor 140. As a result, the aerosol generating article 130, which is at least partially inserted into the sensor 140, is rapidly heated and generates an aerosol.

[0052] In use, the user inhales the aerosol already formed within the aerosol supply device through the nozzle 102. The nozzle 102 may be an open end. The heating assembly 100 may be considered to include an induction heating unit, which includes an induction coil 112 and a sensor 140.

[0053] Figure 1 A and Figure 1 B also illustrates an aerosol generating article 130 partially received within a receptor 140. The receptor 140 can be formed of any material suitable for induction heating. The receptor 140 may include an iron-containing material such as iron, nickel, or cobalt. The receptor 140 defines a receiver to surround and heat the aerosol generating article 130 from the outside.

[0054] The induction coil 112 is made of LITZ wire wound in a spiral manner to provide a helical induction coil 112. The LITZ wire comprises multiple individual wires, which are individually insulated and wound together to form a single wire. The induction coil 112 is made of copper LITZ wire with a circular cross-section.

[0055] The induction coil 112 is configured to generate a changing magnetic field for heating the induction element 114. The induction coil 112 and the sensor 140 are combined together to form an induction heating unit.

[0056] The receptor 140 is hollow and defines a receiver for receiving aerosol-generating materials. For example, an aerosol-generating article 130 can be inserted into the receptor 140. The receptor 140 is tubular with a circular cross-section.

[0057] The sensor 140 is arranged around the aerosol generating article 130 and heats the aerosol generating article 130 from the outside. The aerosol supply device is configured such that when the aerosol generating article 130 is received within the sensor 140, the outer surface of the aerosol generating article 130 abuts the inner surface of the sensor 140. This ensures that heating is most efficient. The aerosol generating article 130 contains aerosol generating material. The aerosol generating material is positioned within the sensor 140. The aerosol generating article 130 may also include other components such as filters, wrapping materials, and / or cooling structures.

[0058] It should be understood that LITZ lines are limited to only one diameter; that is, the diameter of the LITZ line cannot be easily varied along its length. The diameter, number of turns, and thickness of the LITZ line are selected based on the target operating temperature required for heating the aerosol to produce the article. These limitations affect the overall size of the aerosol generation apparatus, as the apparatus needs to be large enough to accommodate the LITZ line.

[0059] Furthermore, the diameter of the LITZ line will also affect the outer surface temperature of the aerosol generation device. The outer surface temperature can be defined as the temperature of the outer surface of the aerosol supply device, such as the surface that the user will come into contact with when using the aerosol supply device.

[0060] In use, once the aerosol-generating article is heated, it is desirable to cool the outer casing temperature as quickly as possible and to virtually prevent it from heating completely. When using conventional LITZ wire as the induction coil, a sufficiently large air gap is required to facilitate this. Therefore, it should be understood that the presence of the air gap will further increase the size of the aerosol supply device.

[0061] It is known to use induction coils to heat receptors, which in turn heat tobacco. The method of winding wires around the receptors is widely used. However, the known arrangement presents challenges for the assembly process. Uniform heat transfer is also desired.

[0062] refer to Figure 2According to various embodiments, a magnetic field generator 200 is disclosed, which includes one or more conductive elements 202. In this example, it includes one or more conductive tracks 202 deposited on or otherwise formed on a flexible substrate 201. The flexible substrate is an electrically insulating substrate or sheet 201. The one or more conductive tracks 202 may, for example, contain copper and may be referred to as copper tracks 202.

[0063] In this example, such as Figure 2 As shown in the left image, a plurality of conductive elements 202 are formed on a substantially planar substrate 201. The plurality of conductive elements 202 extend substantially in a straight line. The plurality of conductive elements 202 are substantially parallel to each other.

[0064] The substrate 201 may be formed of a polymer or plastic and may include, for example, a polyimide (PI) film. The substrate 201 is flexible, allowing it to deform, for example, to take on a substantially tubular shape.

[0065] The magnetic field generator 200 may include one or more connection holes 203, which may be disposed near the edge of the sheet 201. Conductive elements 202 extend to the corresponding connection holes 203. The conductive elements 202 extend from a first edge 204 of the sheet 201 to the respective connection holes 203 of these conductive elements.

[0066] The connecting holes 203 are aligned with each other substantially along a line parallel to the first edge. The connecting holes 203 are located near the second edge 205 of the sheet 201. The second edge 205 is opposite to the first edge 204. The conductive element 202 is angled relative to the first edge 204. The conductive element 202 is angled relative to the second edge 205. The conductive element 202 is angled such that when the substrate 201 is rolled up as described below, the connecting hole 203 of the conductive element 202 is aligned with the next conductive element at the first edge 204 (i.e., the end point of the conductive element is aligned with the beginning point of another conductive element).

[0067] Because the insulating sheet 201 is flexible, it can be rolled into a tube or tubular shape to substantially form an element. The sheet 201 is rolled up so that it overlaps itself. The sheet 201 overlaps itself such that the second edge 205 overlaps with the first edge 204. According to various embodiments, the start and end points of each conductive element can be aligned. According to various embodiments, the two ends of the conductive elements can then be electrically connected to each other via connection holes 203 (e.g., by fusion, gluing, or welding). As a result, some or all of the individual conductive elements 202 can be connected to form a single helical circuit. In practice, the magnetic field generator 200 can be formed as a helical arrangement comprising conductive elements / tracks 202 formed by deforming the substrate 201 into a tubular element. Electricity can be connected to the ends of the tubular elements to generate induction coil units.

[0068] refer to Figure 3 To enhance the performance of the aerosol supply device, it may be desirable to increase the power of the RF electromagnetic waves generated by the magnetic field generator 300. Specifically, according to various embodiments, the power can be multiplied by wrapping or deforming one or more substrates 301 into a tubular element having multiple substrates. In this example, this is achieved by deforming multiple substrates 301a, 301b, and 301c. According to embodiments, each substrate can be connected in parallel to the positive and negative terminals.

[0069] Then, each with a conductive element ( Figure 3 Multiple substrates 301a-c (not shown in the figure) may be rolled up or deformed to form a single cylindrical tubular element.

[0070] In other instances, the base can deform to overlap itself multiple times to provide multiple layers.

[0071] Reference Figure 4 ,like Figure 2 or Figure 3 The tubular element formed can then be externally encased by the magnetic shielding element 207. Therefore, the aerosol supply device can be configured to further include the magnetic shielding element 207. The magnetic shielding element 207 can be arranged to surround at least a portion of the magnetic field generators 200, 300. The magnetic shielding element 207 can include a ferromagnetic material. According to embodiments, the ferromagnetic material can include iron and / or nickel and / or cobalt. The magnetic shielding element 207 can reduce the formation of magnetic fields outside the magnetic field generators 200, 300.

[0072] The aerosol supply device may further include a heat insulation member 208. The heat insulation member 208 may surround at least a portion of the magnetic field generators 200 and 300. The heat insulation member 208 may comprise ceramic or plastic. The heat insulation member 208 may reduce heating of the magnetic field generators 200 and 300 by heat from sensors located within the magnetic field generators 200 and 300.

[0073] The flexible substrate 201 can be formed in a modular arrangement with conductive elements and optional magnetic shielding elements 207 and / or thermal insulation components 208 to facilitate operation and / or assembly, for example, during the manufacturing process, thereby reducing assembly-related costs and / or complexity.

[0074] As a general note, according to embodiments, copper tracks 202 can be deposited onto a flexible polyimide sheet 201, such that the copper tracks function in a manner equivalent to conductive wires. Embodiments are envisioned in which the thickness and / or pitch of the conductive tracks 202 formed on the polyimide sheet 201 can be varied. In particular, by changing the thickness and / or pitch of the conductive tracks 202, different electrical power / thermal effects can be transferred in different (heating) zones as needed.

[0075] The thermal insulation member 208 may be surrounded by at least a portion of the magnetic field generator, and the thermal insulation member 208 may include ceramic or plastic.

[0076] The thickness of one or more conductive elements 202 may be: (i) < 10 µm; (ii) 10-20 µm; (iii) 20-30 µm; (iv) 30-40 µm; (v) 40-50 µm; (vi) 50-60 µm; (vii) 60-70 µm; (viii) 70-80 µm; (ix) 80-90 µm; (x) 90-100 µm; (xi) 100-200 µm; (xii) 200-300 µm; (xiii) 300-400 µm; (xiv) 400-500 µm; (xv) 500-600 µm; (xvi) 600-700 µm; (xvii) 700-800 µm; (xviii) 800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii) 4-5 mm; or (xxiv) > 5 mm. The width of one or more conductive elements 202 may be: (i) < 10 µm; (ii) 10-20 µm; (iii) 20-30 µm; (iv) 30-40 µm; (v) 40-50 µm; (vi) 50-60 µm; (vii) 60-70 µm; (viii) 70-80 µm; (ix) 80-90 µm; (x) 90-100 µm; (xi) 100-200 µm; (xii) 200-300 µm; (xiii) 300-400 µm; (xiv) 400-500 µm; (xv) 500-600 µm; (xvi) 600-700 µm; (xvii) 700-800 µm; (xviii) 800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii) 4-5 mm; or (xxiv) > 5 mm.

[0077] As discussed above, the advantage of the disclosed arrangement is its ease of modularization. The shape of the substrate 201 having the conductive element 202 can be formed by rolling or otherwise deforming, and then combined, for example, with the magnetic shielding sheet 205 and / or the thermal insulation sheet 204, to produce modular components that can be supplied individually and are easy to handle and assemble on the production line.

[0078] Therefore, the aerosol supply device can be configured to include a magnetic field generator 200, 300, which includes one or more flexible substrates 201. Each substrate 201 may include one or more conductive elements 202, wherein each of the plurality of substrates 201 is deformed to form a substantially tubular element. When each substrate 201 is deformed into a tubular element, conductive tracks 202 on each substrate 201 may then be arranged to form one or more helical conductive elements or tracks. The plurality of substrates 201 may include electrical insulators, such as polymers or plastics. In particular, the substrate or each substrate 20 may include polyimide (PI). The thickness of each substrate 201 can be: (i) < 10 µm; (ii) 10-20 µm; (iii) 20-30 µm; (iv) 30-40 µm; (v) 40-50 µm; (vi) 50-60 µm; (vii) 60-70 µm; (viii) 70-80 µm; (ix) 80-90 µm; (x) 90-100 µm; (xi) 100-200 µm; (xii) 200-300 µm; (xiii) 300-400 µm; (xiv) 400-500 µm; (xv) 500-600 µm; (xvi) 600-700 µm; (xvii) 700-800 µm. µm; (xviii)800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii)4-5 mm; or (xxiv) > 5 mm.

[0079] One or more conductive elements 202 may typically comprise metals or metal alloys. For example, one or more conductive elements 201 may comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, brass, bronze, or zinc.

[0080] Figure 4 An embodiment is shown in which the thermal insulation material 208 and the magnet shielding material 207 can also be integrated into the coil. This sub-assembly can be manufactured as a module to simplify the handling and assembly process.

[0081] refer to Figure 5Another embodiment is shown and described, wherein a conductive element 202a (e.g., a copper track) is deposited or otherwise disposed on a substrate 201, such as a polyimide sheet 201. The substrate 201 (e.g., the polyimide sheet 201) is then rolled or wound into a roll such that the substrate or sheet 201 overlaps itself. Specifically, when viewed in cross-section, the roll may include at least 2, 3, 4, 5, 6, 7, 8, 9, or 10 winding portions, i.e., the substrate or sheet 201 may be arranged to overlap itself at least 2, 3, 4, 5, 6, 7, 8, 9, or 10 times. According to various embodiments, and as... Figure 5 As shown, the conductive element may have a positive terminal and a negative terminal, which can be connected to a power source (e.g., a battery and a power control unit) to form a magnetic field generator (e.g., an induction coil unit).

[0082] The formed magnetic field generator may include a flexible substrate 201, wherein the substrate 201 includes one or more conductive elements 202a, and wherein the substrate 201 is wound to form a roll such that the substrate 201 overlaps itself. The one or more conductive elements 202a may include multiple conductive tracks, such as... Figure 5 As shown, these conductive tracks are arranged to form multiple parallel electrical paths.

[0083] According to various embodiments, an aerosol supply system is disclosed, comprising: an aerosol supply device as described above; and an aerosol generating article comprising aerosol generating material.

[0084] Figure 6 A method 600 for manufacturing a magnetic field generator for an aerosol supply device according to one embodiment is shown. Method 600 includes a first step 601 of providing a plurality of flexible substrates, each substrate including one or more conductive elements. Method 600 then includes a second step 602 of deforming the plurality of substrates to form a substantially tubular element.

[0085] Figure 7 A method 700 for manufacturing a magnetic field generator for an aerosol supply device according to another embodiment is shown. Method 700 includes a first step 701 of providing a flexible substrate, wherein the substrate includes one or more conductive elements. Method 700 then includes a second step 702 of winding the substrate to form a roll such that the substrate overlaps itself.

[0086] The method further includes depositing, sputtering, laser-activated, implanting, etching, or printing one or more conductive elements on or onto one or more substrates.

[0087] A method for generating an aerosol is also disclosed, comprising providing an aerosol supply device including a magnetic field generator comprising a plurality of flexible substrates. Each substrate includes one or more conductive elements. The plurality of substrates are deformed to form a substantially tubular element. The method further comprises inserting an aerosol generating article comprising aerosol generating material into the aerosol supply device. The method may also include activating the aerosol supply device.

[0088] A method for generating an aerosol is also disclosed, comprising providing an aerosol supply device including a magnetic field generator comprising a flexible substrate. The substrate includes one or more conductive elements, wherein the substrate is wound to form a roll such that the substrate overlaps itself. The method may further include inserting an aerosol generating article comprising aerosol generating material into the aerosol supply device and activating the aerosol supply device.

[0089] A further embodiment is envisioned in which a substrate is formed by guiding a laser onto the surface of a flexible support to create a laser-activated region. This substrate is then deformed or wound to form a magnetic field generator (which operates in a manner equivalent to an induction coil). The flexible support can be formed from a thermoplastic material, such as polyetheretherketone (PEEK) already doped with a metal inorganic compound. The laser generates the laser-activated region on the flexible support, which can then be metallized (further) using, for example, a chemical plating process to establish one or more conductive layers, such as copper.

[0090] According to various embodiments, the laser can be arranged to form a conductive track structure on a non-conductive support. The conductive track structure can be formed from a metal core, which is generated by decomposing a very finely distributed non-conductive metal compound contained in the flexible support. The non-conductive metal compound contained in the flexible support material can be decomposed or otherwise activated by irradiating a portion of the flexible support material with electromagnetic radiation.

[0091] Non-conductive metal compounds may include thermally stable inorganic oxides that are stable and insoluble in acidic or alkaline metallization baths, and the thermally stable inorganic oxides are selected from the group consisting of higher oxides that contain at least two different kinds of cations and have a spinel structure or spinel-like structure and remain unchanged in the non-irradiated region of the flexible support material.

[0092] Traditional spinel is a mixed metal oxide of magnesium and aluminum, but magnesium can be wholly or partially replaced by iron, zinc, and / or manganese, and aluminum can be replaced by iron and / or chromium. The mixed oxide structure of spinel-like materials can also contain nickel and / or cobalt cations.

[0093] According to various embodiments, the aerosol supply device may be configured to include a sensor and a magnetic field generator formed as described above. The sensor may be located within a volume defined by the magnetic field generator. The sensor may be formed of any material suitable for induction heating. For example, the sensor may include a metal. In some instances, the sensor may include: non-ferrous metals such as copper, nickel, titanium, aluminum, tin, or zinc; and / or ferrous materials such as iron, nickel, or cobalt. Additionally or alternatively, the sensor may include a semiconductor such as silicon carbide, carbon, or graphite.

[0094] The receptor can have any suitable shape. In one embodiment, the receptor can define a receiver to surround and heat the aerosol-generating article from the outside. In other embodiments, one or more receptors can be substantially elongated, arranged to penetrate the aerosol-generating article and heat it internally.

[0095] As described above, a magnetic field generator formed from one or more flexible substrates can be configured to generate a varying magnetic field for a heating sensor, and can be used in accordance with the above reference. Figure 1 A and Figure 1 The induction coil 112 described in B operates in essentially the same manner or otherwise. A changing magnetic field generates eddy currents within the sensor, thereby rapidly heating the sensor to its maximum operating temperature within a short period (e.g., within 20 seconds, 15 seconds, 12 seconds, 10 seconds, 5 seconds, or 2 seconds) after an alternating current is supplied to the magnetic field generator. The sensor may comprise a single sensor. Optionally, multiple sensors may be provided.

[0096] As described above, the ends of a magnetic field generator formed by one or more flexible substrates can be connected to a controller, such as a PCB. The controller may include a proportional-integral-derivative (PID) controller.

[0097] According to various embodiments, the receptor may be hollow and may form or define a receiver in which the aerosol-generating material can be received. For example, an aerosol-generating article may be inserted into the receptor. The receptor may be tubular and have a circular cross-section. The receptor may be arranged to surround the aerosol-generating article to heat the aerosol-generating article from the outside.

[0098] According to various embodiments, the magnetic field generator can be formed from a flexible substrate using a process called laser direct forming (LDS). According to different embodiments, the laser can be used to activate the surface of the flexible substrate, which may include a thermoplastic material, such as polyetheretherketone (PEEK), which may have been doped with a metallic inorganic compound. The laser generates one or more laser-activated regions on the flexible substrate, which can then be (optionally) metallized using, for example, a chemical plating process to establish one or more conductive layers, such as copper.

[0099] According to this embodiment, the flexible substrate can be shaped to form a uniform helical induction coil or other magnetic field generator. However, other embodiments are also contemplated, in which the magnetic field generator can have different configurations.

[0100] Various novel electrode structures can also be envisioned. For example, one or more conductive elements disposed on one or more flexible substrates can be arranged with different thicknesses or with thicknesses varying along the length of the final conductive path. It is conceivable, for example, that the thickness of one or more conductive elements can be non-constant. The magnetic field strength of a coil is well known to be given by the following formula: (1) Where H is the magnetic field strength in ampere-turns per meter (At / m), N is the number of turns in the coil, I is the current flowing through the coil in amperes (A), and L is the length of the coil in meters (m).

[0101] It is known that the resistance R of a wire (electrode) is inversely proportional to the cross-sectional area of ​​the wire (electrode): (2) Where ρ is resistivity, L is the length of the line (electrode), and A is the cross-sectional area of ​​the line (electrode).

[0102] Therefore, as the cross-sectional area A of the wire (or electrode or conductive element) increases, it will be understood that the resistance of the wire (or electrode or conductive element) will decrease. As a result, for a given voltage, a larger current can pass through a wire (or electrode or conductive element) with a relatively large cross-sectional area compared to a wire (or electrode or conductive element) with a relatively small cross-sectional area.

[0103] Equation 1 above shows that for a line (or electrode or conductive element) with a relatively large cross-sectional area, the magnetic field strength increases.

[0104] Therefore, a coil or electrode structure or conductive element is provided, wherein the thickness of the coil or electrode or conductive element varies at different locations along the length of the coil or electrode or conductive element, such that the magnetic field strength can vary along the length of the coil or electrode or conductive element. For example, according to an embodiment, the coil or electrode or conductive element may include a first segment having a first cross-sectional area and a second segment having a second different cross-sectional area. As a result, the final magnetic field strength generated by the alternating current passing through these two segments may also be different. Consequently, a first current can be induced in a first corresponding segment of the sensor, and a second different current can be induced in a second different segment of the sensor (or in a separate sensor). This makes the resulting thermal effect different in the two different segments of the sensor.

[0105] According to various embodiments, providing a coil, electrode, or conductive element with an increased thickness or cross-sectional area enables the generation of a magnetic field with a higher amplitude than that of a coil, electrode, or conductive element with a smaller thickness or cross-sectional area. As a result, a coil, electrode, or conductive element can be provided that exhibits different heating characteristics at different axial positions along the axial length of the aerosol supply device. For example, a region with increased thickness will heat its adjacent receptor region to a greater extent than a region with decreased thickness.

[0106] According to various embodiments, the coil, electrode, or conductive element may have a uniform thickness and / or width, or a thickness and / or width varying along its length. According to various embodiments, the coil, electrode, or conductive element may have a rectangular cross-sectional profile having a width in a direction parallel to the surface of the flexible substrate, and a depth or thickness in a direction perpendicular to the surface of the flexible substrate. The width of the coil, electrode, or conductive element may be: (i) < 10 µm; (ii) 10-20 µm; (iii) 20-30 µm; (iv) 30-40 µm; (v) 40-50 µm; (vi) 50-60 µm; (vii) 60-70 µm; (viii) 70-80 µm; (ix) 80-90 µm; (x) 90-100 µm; or (xi) > 100 µm. The depth or thickness of the coil, electrode, or conductive element may be: (i) < 10 µm; (ii) 10–20 µm; (iii) 20–30 µm; (iv) 30–40 µm; (v) 40–50 µm; (vi) 50–60 µm; (vii) 60–70 µm; (viii) 70–80 µm; (ix) 80–90 µm; (x) 90–100 µm; or (xi) > 100 µm.

[0107] According to various embodiments, if the coil, electrode, or conductive element comprises only a laser-activated region of a flexible substrate, the coil, electrode, or conductive element can have a relatively thin thickness (e.g., < 1 µm). The thickness of the coil, electrode, or conductive element can be increased by depositing one or more conductive layers on the laser-activated region. The one or more conductive layers deposited on the laser-activated region can have a thickness > 10 µm.

[0108] According to various embodiments, the coil, electrode, or conductive element may have a cross-sectional area selected from the group consisting of: (i) < 100 µm 2 (ii) 100-200 µm 2 (iii) 200-300 µm 2 (iv) 300-400 µm 2 (v) 400-500 µm 2 (vi) 500-600 µm 2 (vii) 600-700 µm 2 (viii) 700-800 µm 2 (ix) 800-900 µm 2 ;(x) 900-1000 µm 2 ; and (xi) > 1000 µm 2 .

[0109] According to various embodiments, the coil, electrode, or conductive element may have a constant number of turns per unit length, or the number of turns per unit length may vary in different sections of the coil, electrode, or conductive element. For example, the coil, electrode, or conductive element disposed on a flexible substrate as described above may have a total length L, and the coil, electrode, or conductive element may be considered to comprise two sections. The coil, electrode, or conductive element may comprise two equal sections L1 and L2, i.e., length L1 is the same as length L2, and the number of turns per unit length in section L1 is the same as the number of turns per unit length in section L2. However, embodiments are also contemplated in which the number of turns per unit length in section L1 may be greater than the number of turns per unit length in section L2, or vice versa. Embodiments are also contemplated in which the coil, electrode, or conductive element may comprise multiple sections, and at least some of these sections may have different or the same number of turns per unit length.

[0110] Variations in the number of turns can increase or decrease the rate at which the sensor reaches its maximum operating temperature. If desired, this arrangement can provide asymmetric heating of the aerosol-generating article along its length.

[0111] In this example, the pitch of the coil, electrode, or conductive element as described above may not remain constant. Changing the pitch of the coil, electrode, or conductive element can alter the heating characteristics of the aerosol supply device at different locations on the coil, electrode, or conductive element. For example, a region with a smaller pitch would mean an increase in the number of turns per unit length, resulting in a higher degree of heating of its adjacent sensor region compared to the region near a section of coil, electrode, or conductive element with fewer turns per unit length.

[0112] As will be understood, the number of turns in a coil is inversely proportional to its pitch. Therefore, a change in the pitch of the coil, electrode, or conductive element will consequently cause a change in the number of turns in the coil, electrode, or conductive element, which can increase or decrease the rate at which the sensor reaches its maximum operating temperature. If desired, this arrangement can provide asymmetric heating of the aerosol-generating article along its length.

[0113] According to various embodiments, the coil, electrode, or conductive element may have a pitch that is substantially constant per unit length, and therefore a number of turns that is substantially constant per unit length. The height of a complete spiral turn in the coil, electrode, or conductive element may be substantially constant along at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% of the axial length of the coil, electrode, or conductive element.

[0114] In the example, the coil or electrode or conductive element may have a helical segment with a first pitch P1 or P1 turns per unit length (i.e., the height of one complete helical turn is P1), and a second different helical segment with a second pitch P2 or P2 turns per unit length (i.e., the height of one complete helical turn is P2), such that P1 ≠ P2.

[0115] In the example, the coil or electrode or conductive element may have a substantially constant width and / or substantially constant length and / or substantially constant thickness along at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% of the axial length of the respective coil.

[0116] In an example, the coil, electrode, or conductive element may have: a first helical segment having a width W1 and / or a length L1 and / or a thickness T1; and a second, distinct helical segment having a width W2 and / or a length L2 and / or a thickness T2, such that W1 ≠ W2 and / or L1 ≠ L2 and / or T1 ≠ T2. It should be understood that this configuration is suitable for applications such as references. Figure 1 A and Figure 1 The conventional induction coil described in B is impossible to implement because the number of turns per unit length of a conventional induction coil is constant, and the LITZ coil has a constant thickness and diameter.

[0117] Coils, electrodes, or conductive elements (or more generally, electrode arrangements) can be formed, deposited, or coated in and / or on a flexible substrate, such that the coils, electrodes, conductive elements, or electrode arrangements have square, rectangular, or polygonal cross-sectional profiles. The flexible substrate may include thermoplastic materials such as polyetheretherketone (PEEK). According to various embodiments, the diameter of the coils, electrodes, conductive elements, or electrode arrangements can be in the range of <10 mm, 10-11 mm, 11-12 mm, 12-13 mm, or 14-15 mm.

[0118] Using laser direct forming technology, coils, electrodes, conductive elements, or electrode arrangements are formed in and / or on a flexible substrate, thereby forming coils, electrodes, conductive elements, or electrode arrangements integrated with or incorporated into the flexible substrate. (Similar to references...) Figure 1 A and Figure 1 Compared to the conventional arrangements described in B, this advantageously reduces the diameter of the required flexible substrate (in the case of a tubular flexible substrate). It should be understood that integrating coils or electrodes or conductive elements into a shaped flexible substrate can provide a more compact arrangement.

[0119] The compact, flexible substrate of the disclosed arrangement also means that, compared to conventional arrangements (such as references) Figure 1 A and Figure 1 Compared to those described in B, any air gap between the flexible substrate and the housing of the aerosol supply device can be reduced. This also results in more efficient cooling. The increased efficiency allows for the use of smaller batteries to power the aerosol supply device during use, thus reducing charging time. Overall, this allows for more compact, lighter, more robust, customizable, and more energy-efficient heating arrangements.

[0120] Coils, electrodes, or conductive elements can be formed by depositing, coating, or otherwise forming electrode structures on the outer surface of a flexible substrate. However, in other instances, coils, electrodes, conductive elements, or electrode structures can be deposited, coated, or otherwise formed on the inner surface of a flexible substrate via a laser direct forming process.

[0121] According to one embodiment, the length L of the coil, electrode, or conductive element can be substantially 585 mm, the total number of turns can be 18, and the coil pitch can be substantially 2 mm. However, other embodiments are considered, in which the length L of the coil can be shorter or longer than 585 mm. Similarly, the number of turns can be less than or greater than 18. It is also conceivable that the coil pitch can be less than or greater than 2 mm.

[0122] According to various embodiments, the flexible support can be molded from a material with high thermal stability, good isotropic component behavior, and suitability for metallization. PEEK has been found to be particularly suitable for this process, but other materials, including polyphthalamide (PPA) or liquid crystal polymers (LCP), can also be used. As mentioned above, the flexible support can alternatively be formed from polyimide.

[0123] The flexible support can be formed from a thermoplastic doped with a non-conductive metallic inorganic compound. For example, the non-conductive metallic inorganic compound can contain copper. However, other embodiments are considered where the additives can contain nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

[0124] According to various embodiments, the flexible support can be made of thermoplastic having a composition comprising: (i) 20 to 90 wt% thermoplastic resin; (ii) laser direct molding additive; and (iii) optional ceramic filler particles, which may not have the laser direct molding additive function.

[0125] According to various embodiments, the laser direct forming additive may include a non-conductive metallic inorganic compound. However, other embodiments are considered, in which the laser direct forming additive may include a conductive metal oxide. The resistivity of the conductive metal oxide may be at most 5 x 10⁻⁶. 3 Ω·cm. Conductive metal oxides may include at least one of Group n and / or Group n+1 metals of the periodic table, where n is an integer from 3 to 13. Suitable Group n and / or Group n+1 metals of the periodic table include, for example, Group 4 (titanium, zirconium), Group 5 (vanadium, niobium), Group 6 (chromium, molybdenum), Group 7 (manganese), Group 8 (iron, ruthenium), Group 9 (cobalt, rhodium, iridium), Group 10 (nickel, palladium, platinum), Group 11 (copper, silver, gold), Group 12 (zinc, cadmium), and Group 13 (aluminum, gallium, indium). Suitable Group n metals of the periodic table further include Group 3 metals (scandium, yttrium). Suitable Group n+1 metals of the periodic table further include Group 14 metals (germanium, tin). Conductive metal oxides may include zinc and aluminum. For example, conductive metal oxides may include aluminum-doped zinc oxide.

[0126] According to another embodiment, the laser direct forming additive may include calcium copper titanate. The thermoplastic resin may include resins such as polycarbonates, particularly aromatic polycarbonates, polyamides, polyesters, polyesteramides, polystyrene, polymethyl methacrylate, polyphenylene ether, liquid crystal polymers (LCPs), polyether ether ketones (PEEKs), cyclic olefin (co) polymers (COPs), or combinations thereof. The resin may be a homopolymer, copolymer, or mixture thereof, and may be branched or unbranched.

[0127] According to various examples, the conductive orbital structure can be formed on a non-conductive support material (i.e., a flexible substrate) comprising a metallization layer applied to a metal core created by decomposing a very finely distributed non-conductive metal compound contained in the flexible support material. The non-conductive metal compound contained in the flexible support material can be decomposed by irradiating portions of the flexible support material with electromagnetic radiation or otherwise activated. The non-conductive metal compound can include thermally stable inorganic oxides that are stable and insoluble in acidic or alkaline metallization baths, and are selected from the group consisting of higher oxides containing at least two different types of cations and having a spinel or spinel-like structure that remains unchanged in the non-irradiated regions of the flexible support material. Conventional spinel is a mixed metal oxide of magnesium and aluminum, but magnesium can be wholly or partially replaced by iron, zinc, and / or manganese, and aluminum can be replaced by iron and / or chromium. The spinel-like mixed oxide structure can also contain nickel and / or cobalt cations.

[0128] According to various embodiments, conductive track structures can be formed on a non-conductive support having at least one surface formed of a non-conductive support material having at least one thermally stable, spinel-based, non-conductive metal oxide that is stable and insoluble when dispersed in an acidic or alkaline metallization bath. The process involves a radiated region of a flexible support having conductive tracks thereon, which is irradiated with electromagnetic radiation to decompose the non-conductive metal oxide and release metal nuclei, subsequently metallizing the irradiated region by chemical reduction. According to various embodiments, non-conductive metal compounds of thermally highly stable inorganic oxides, stable and insoluble in acidic or alkaline metallization baths, and being advanced oxides having a spinel structure or a spinel-like structure, can be used. As a result, these metal compounds can remain unchanged on the surface of the flexible support material even in unirradiated areas. The inorganic oxides used are heat-resistant, so that they remain stable even after exposure to welding temperatures, i.e., they do not become conductive, and they remain stable in the bath used for metallization.

[0129] According to various embodiments, the spinel or spinel-like structure may contain copper, chromium, iron, cobalt, nickel, or a mixture of two or more of the foregoing. In particular, the spinel or spinel-like structure may contain copper.

[0130] Non-conductive support materials may include thermoplastic or thermosetting synthetic resin materials. Non-conductive support materials may contain one or more inorganic fillers, such as silicic acid and / or silicic acid derivatives.

[0131] According to various embodiments, a spinel-based, thermally stable, non-conductive advanced oxide can be used. This advanced oxide contains at least two different types of cations and is stable and insoluble in acidic or alkaline metallization baths. The cations are mixed into a flexible support material, which can then be processed into parts or applied as a coating to parts. In laser direct forming processes, metal nuclei are released in regions of the conductive structure to be produced using electromagnetic radiation. These regions are then chemically reduced and metallized, and the inorganic metal compound in the form of a spinel-based advanced oxide can remain on the surface of the flexible support material in the unirradiated areas. Furthermore, the inorganic advanced oxide containing at least two different cations has sufficient heat resistance, thus allowing for the composite or injection molding of modern high-temperature plastics.

[0132] Electromagnetic radiation can be used to simultaneously release a metal nucleus and achieve ablation, while simultaneously forming an adhesion-promoting surface. This provides a simple way to achieve excellent adhesion strength for subsequently deposited metal conductor tracks.

[0133] The inorganic oxide may comprise copper, chromium, iron, cobalt, nickel, or mixtures thereof. The non-conductive support material may comprise thermoplastic or thermosetting synthetic resin materials. However, other embodiments are considered, wherein the flexible support material may comprise non-conductive materials, such as ceramics. The non-conductive support material may comprise one or more inorganic fillers, such as silicic acid and / or silicic acid derivatives.

[0134] According to various embodiments, a laser can be used to generate an electromagnetic radiation beam that can be directed to the surface of a flexible substrate to release a metal nucleus at the location where the laser beam strikes the surface of the flexible substrate. The effectively released metal nucleus forms a catalyst or anchor for subsequent (optionally) deposition of one or more conductive layers on the laser-activated region by immersing the flexible substrate in a bath. The wavelength of the laser can be, for example, 248 nm, 308 nm, 355 nm, 532 nm, 1064 nm, or 10600 nm.

[0135] It should be understood that, according to various embodiments, depositing one or more conductive layers on the laser-activated region is unnecessary. Instead, some embodiments are envisioned in which the resulting laser-activated region may include a metal core, such as copper atoms that have essentially been released from the doped thermoplastic support. The metal core forming the laser-activated region may have a depth of <1 µm or from 1 µm to 10 µm and may form conductive traces or tracks on the surface of the flexible support.

[0136] In the first step, a laser beam can be directed onto a portion of the flexible support. The laser activates the surface of the thermoplastic material of the flexible support, causing a metal core to form or be released from the flexible support surface. The metal core can form a thin surface layer with a thickness of <5 µm or <1 µm. In addition to activating additives in the flexible support to form a laser-activated region including the metal core, the laser beam can also create a micro-roughened surface that helps anchor one or more layers of conductive material to the laser-activated region in subsequent optional metallization steps.

[0137] The surface roughness of the conductive pattern surface is expected to be in the range of < 0.025 µm, 0.025-0.05 µm, 0.05-1 µm, 0.1-1 µm, 1-5 µm, 5-10 µm, 10-15 µm, or >15 µm. According to other embodiments, the surface roughness can be in the range of < 0.1 µm, 0.1-1 µm, 1-10 µm, 10-20 µm, 20-30 µm, 30-40 µm, 40-50 µm, or >50 µm.

[0138] If the desired thickness of the electrode structure formed on the flexible support is greater than the thickness of the laser-activated region formed in the first step of the laser forming and initiation process, an optional metallization step can be used to further increase the thickness of the electrode structure formed on the surface of the flexible support. Before performing the second step, the flexible support in which the laser-activated region is formed can be cleaned. The flexible support can be cleaned using any suitable conventional process, including spraying with a water-based, semi-aqueous, or solvent-based cleaning solution, or by ultrasonic cleaning methods known in the art. Once the cleaning process is complete, the metallization step can then begin, which deposits one or more conductive layers onto the conductive tracks initially formed in the flexible support.

[0139] The metallization step uses a chemical plating metallization process to add metal to the laser-activated additive layer. A flexible support can be placed in a bath where chemical plating metallization can be performed. The bath can include, for example, copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc. When placed in the bath, the thickness of the conductive tracks or traces formed on the flexible support may increase at a rate in the range of 8-12 µm / h. This process can be continued until the desired electrode thickness is obtained.

[0140] It should be understood that each conductive layer may comprise the same conductive material, such as copper, or a series of layers may be deposited, each comprising a different material selected from copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, and zinc. The thickness of one or more conductive layers deposited on the laser-activated region may be: (i) < 10 µm; (ii) 10–20 µm; (iii) 20–30 µm; (iv) 30–40 µm; (v) 40–50 µm; (vi) 50–60 µm; (vii) 60–70 µm; (viii) 70–80 µm; (ix) 80–90 µm; or (x) 90–100 µm.

[0141] After the metallization step is completed, a final (and optional) surface polishing step can be performed. In the final (optional) step, an optional and application-specific coating can be deposited on top of the combined conductive tracks or electrodes using the same or similar electroless metallization process described above with reference to step two. For example, a flexible substrate can be placed in a bath containing the desired coating. The coating may include copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

[0142] Although the second and final steps described above involve electroless metallization, other coating techniques can also be considered, including electroless plating, galvanic plating, or autocatalytic plating processes, in which one or more laser-activated regions can come into contact with a liquid solution to trigger a chemical or catalytic reaction that deposits metal particles present in the liquid solution onto one or more laser-activated regions, thereby forming one or more conductive layers.

[0143] The embodiments described herein are provided only to aid in understanding and teaching the claimed features. These embodiments are provided only as illustrative examples of implementation and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures and / or other aspects disclosed herein should not be considered as limitations on the invention as defined by the claims or on the equivalents of the claims, and other embodiments may be utilized and modifications may be made without departing from the scope of the claims. Embodiments of the invention may suitably include various combinations of the disclosed elements, components, features, parts, steps, devices, etc., other than those specifically described herein, constituting or substantially constituting those 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 supply device, comprising: A magnetic field generator includes a plurality of flexible substrates, wherein each substrate includes one or more conductive elements, and wherein the plurality of substrates are deformed to form a substantially tubular element.

2. The aerosol supply device according to claim 1, wherein, The essentially tubular element comprises one or more helical conductive elements.

3. An aerosol supply device, comprising: A magnetic field generator includes a flexible substrate, wherein the substrate includes one or more conductive elements, and wherein the substrate itself overlaps to form a substantially tubular element.

4. The aerosol supply device according to claim 3, wherein, The one or more conductive elements include: a plurality of conductive tracks arranged to form a plurality of substantially parallel electrical paths.

5. The aerosol supply device according to any one of the preceding claims, wherein, The substrate or each substrate contains an electrical insulator.

6. The aerosol supply device according to any one of the preceding claims, wherein, The substrate, or each substrate, contains a polymer or plastic.

7. The aerosol supply device according to any one of the preceding claims, wherein, The substrate or each substrate contains polyimide ("PI").

8. The aerosol supply device according to any one of the preceding claims, wherein, The thickness of the substrate, or each substrate, is: (i) < 10 µm; (ii) 10–20 µm; (iii) 20–30 µm; (iv) 30–40 µm; (v) 40–50 µm; (vi) 50–60 µm; (vii) 60–70 µm; (viii) 70–80 µm; (ix) 80–90 µm; (x) 90–100 µm; (xi) 100–200 µm; (xii) 200–300 µm; (xiii) 300–400 µm; (xiv) 400–500 µm; (xv) 500–600 µm; (xvi) 600–700 µm; (xvii) 700–800 µm; (xviii) 800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii) 4-5 mm; or (xxiv) > 5 mm.

9. The aerosol supply device according to any one of the preceding claims, wherein, The one or more conductive elements comprise metal or metal alloy.

10. The aerosol supply device according to any one of the preceding claims, wherein, The one or more conductive elements comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, brass, bronze, or zinc.

11. The aerosol supply device according to any one of the preceding claims, further comprising a magnetic shielding element.

12. The aerosol supply device according to claim 11, wherein, The magnetic shielding element is arranged to surround at least a portion of the magnetic field generator.

13. The aerosol supply device according to claim 11 or 12, wherein, The magnetic shielding element contains ferromagnetic material.

14. The aerosol supply device according to claim 13, wherein, The ferromagnetic material comprises one or more of the following: (i) iron; (ii) nickel; and (iii) cobalt.

15. The aerosol supply device according to any one of the preceding claims, further comprising a heat insulation member.

16. The aerosol supply device according to claim 15, wherein, The heat insulation component is surrounded by at least a portion of the magnetic field generator.

17. The aerosol supply device according to claim 15 or 16, wherein, The thermal insulation component comprises ceramic or plastic.

18. The aerosol supply device according to any one of the preceding claims, wherein, The thickness of the one or more conductive elements is: (i) < 10 µm; (ii) 10-20 µm; (iii) 20-30 µm; (iv) 30-40 µm; (v) 40-50 µm; (vi) 50-60 µm; (vii) 60-70 µm; (viii) 70-80 µm; (ix) 80-90 µm; (x) 90-100 µm; (xi) 100-200 µm; (xii) 200-300 µm; (xiii) 300-400 µm; (xiv) 400-500 µm; (xv) 500-600 µm; (xvi) 600-700 µm; (xvii) 700-800 µm; (xviii) 800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii) 4-5 mm; or (xxiv) > 5 mm.

19. The aerosol supply device according to any one of the preceding claims, wherein, The width of the one or more conductive elements is: (i) < 10 µm; (ii) 10-20 µm; (iii) 20-30 µm; (iv) 30-40 µm; (v) 40-50 µm; (vi) 50-60 µm; (vii) 60-70 µm; (viii) 70-80 µm; (ix) 80-90 µm; (x) 90-100 µm; (xi) 100-200 µm; (xii) 200-300 µm; (xiii) 300-400 µm; (xiv) 400-500 µm; (xv) 500-600 µm; (xvi) 600-700 µm; (xvii) 700-800 µm; (xviii) 800-900 µm; (xix) 900-1000 µm; (xx) 1-2 mm; (xxi) 2-3 mm; (xxii) 3-4 mm; (xxiii) 4-5 mm; or (xxiv) > 5 mm.

20. An aerosol supply system, comprising: Aerosol supply device according to any one of the preceding claims; as well as Aerosol-generating products, including aerosol-generating materials.

21. A method for manufacturing a magnetic field generator for an aerosol supply device, the method comprising: A plurality of flexible substrates are provided, wherein each substrate includes one or more conductive elements; as well as The plurality of substrates are deformed to form a substantially tubular element.

22. A method for manufacturing a magnetic field generator for an aerosol supply device, the method comprising: A flexible substrate is provided, wherein the substrate includes one or more conductive elements; as well as The substrate is deformed such that it overlaps itself to form a substantially tubular element.

23. The method of claim 21 or 22, further comprising depositing, sputtering, laser-activated, implanting, etching, or printing the one or more conductive elements on or onto the one or more substrates to provide a flexible substrate comprising the one or more conductive elements.

24. A method for generating an aerosol, comprising: An aerosol supply device is provided, the aerosol supply device including a magnetic field generator, the magnetic field generator including a plurality of flexible substrates, wherein each substrate includes one or more conductive elements, wherein the plurality of substrates are deformed to form a substantially tubular element. An aerosol-generating article containing aerosol-generating materials is inserted into the aerosol supply device; and Start the aerosol supply device.

25. A method for generating an aerosol, comprising: An aerosol supply device is provided, the aerosol supply device including a magnetic field generator, the magnetic field generator including a flexible substrate, wherein the substrate includes one or more conductive elements, wherein the substrate itself overlaps to form a substantially tubular element; An aerosol-generating article containing aerosol-generating materials is inserted into the aerosol supply device; and Start the aerosol supply device.

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