Aerosol supply device

Abstract

An aerosol-forming article (110) comprising: a substantially planar first surface comprising an aerosol-generating material (306); and a substantially planar second surface opposite the first surface such that an airflow path is defined between the first surface and the second surface. The airflow path between the first surface and the second surface is free of obstacles at the aerosol-generating material.

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. Efforts have been made to provide alternatives to these tobacco-burning products by developing products that release compounds without combustion. Examples of such products include heating devices that release compounds by heating rather than burning materials. The materials 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 substantially planar first surface comprising an aerosol-generating material; and a substantially planar second surface opposite the first surface, such that an airflow path is defined between the first and second surfaces. The airflow path between the first and second surfaces can be unobstructed at the aerosol-generating material.

[0004] The first surface may include multiple discrete regions of the aerosol-generating material. The discrete regions may be longitudinally offset from each other. The airflow path between the first and second surfaces may be unobstructed at each discrete region. The airflow path between the first and second surfaces may be unobstructed across the entire region of the aerosol-generating material. The airflow path between the first and second surfaces may be unobstructed in the region between the first and second discrete regions. The aerosol-forming article may be composed of a layered structure. The layered structure may include a first layer defining the first surface and a second layer defining the second surface. The layered structure may include at least one intermediate layer. The at least one intermediate layer may include a first intermediate layer. The first intermediate layer may include cutouts in the aerosol-generating material such that the airflow path between the first and second surfaces is unobstructed at the aerosol-generating material. Any of the above-described aerosol-forming articles may also include an outlet. The outlet may be formed in the first intermediate layer. Any of the above-described aerosol-forming articles may also include a flow control feature positioned such that air from the inlet impinges on the flow control feature. The flow control feature may be configured to reduce the airflow velocity. The flow control feature may be located upstream of the aerosol generating material. The flow control feature may be formed in a first intermediate layer. The first intermediate layer may include longitudinally extending spacers. An airflow path may be located between the longitudinally extending spacers. The longitudinally extending spacers may be laterally offset from the aerosol generating material such that the airflow path between the first and second surfaces is unobstructed at the aerosol generating material. Any of the above-described aerosol forming articles may further include an inlet configured to allow air to flow into the article between the first and second surfaces. In an example, the article further includes an inlet and an outlet, wherein at least one of the inlet and outlet has a cross-sectional area smaller than the cross-sectional area of ​​the airflow path. The cross-sectional areas of both the inlet and outlet may be smaller than the cross-sectional area of ​​the airflow path. The minimum cross-sectional area of ​​the airflow path is greater than the cross-sectional area of ​​at least one of the inlet and outlet.

[0005] In another aspect, an aerosol supply system is provided. The aerosol supply system includes any one of the aforementioned aerosol forming articles, and an aerosol supply device configured to heat the aerosol generating material to generate an aerosol. Attached Figure Description

[0006] Some implementation methods will now be described by way of example and with reference to the accompanying drawings, in which: Figure 1 A side view of the aerosol supply system is shown. Figure 2 A schematic cross-sectional view of the article in a plane parallel to the longitudinal axis of the article is shown; Figure 3 An exploded view of the substrate and aerosol-generating materials is shown; Figure 4A An exploded view of the intermediate layer of the product is shown; Figure 4B A cross-sectional view of the third intermediate layer of the product is shown; Figure 4C A cross-sectional view of the third intermediate layer is shown, illustrating the flow control feature. Figure 5 The graph showing the relationship between aerosol carrying capacity and gap size is shown. Figure 6A The graph shows the relationship between pressure drop and various inlet areas; Figure 6B The graph shows the relationship between aerosol delivery rate and various inlet sizes; Figure 7A A graph showing aerosol delivery rates for articles with different characteristics (including different outlet areas) is presented. Figure 7B The graph showing the relationship between aerosol delivery rate and outlet area is shown. Figure 8 The test results for generating the product are shown. Figure 7A Exploded views of the structural components of various products shown in the data; Figure 9 A graph showing aerosol delivery rates for articles with different characteristics is presented. Figure 10 The test results for generating the product are shown. Figure 9 Exploded views of the structural components of various products shown in the data; and Figure 11 A schematic cross-sectional view of the article in a plane perpendicular to the longitudinal axis of the article is shown. Detailed Implementation

[0007] As used herein, the term "aerosol-generating material" is a material capable of generating aerosols, for example, when heated, irradiated, or powered in any other way. Aerosol-generating materials may be in the form of, for example, a solid, liquid, or gel, 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 the form of, for example, a solid, liquid, gel, wax, etc. Aerosol-generating materials may also be, for example, a combination or mixture of materials. Aerosol-generating materials may also be referred to as "inhalable materials."

[0008] The aerosol-generating material may comprise a binder and an aerosol-forming agent. Optionally, an active agent 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 be soluble in the solvent or insoluble 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.

[0009] Aerosol-generating materials may include or may be "amorphous solids". Amorphous solids may be "monolithic solids". In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material that can retain some fluid (such as a liquid) within it. 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.

[0010] Aerosol-generating materials may include aerosol-generating membranes. Aerosol-generating membranes may include or be sheets, which may optionally be shredded to form shredded sheets. The aerosol-generating sheets or shredded sheets may be substantially tobacco-free.

[0011] According to this disclosure, a "non-combustible" aerosol supply system is an aerosol supply system in which the aerosol generating material is not burned or ignited, and at least one substance is delivered to the user.

[0012] In some implementations, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0013] In some implementations, the non-combustible aerosol supply system is an electronic cigarette, also known as an atomizing device or electronic nicotine delivery system (END); however, it should be noted that the presence of nicotine in the aerosol generating material is not necessary.

[0014] In some implementations, the non-combustible aerosol supply system is a heating system for the aerosol generating material, also known as a heated non-combustible system. An example of such a system is a tobacco heating system.

[0015] In some embodiments, the non-combustible aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to generate aerosols, wherein one or more of these aerosol-generating materials can be heated. Each aerosol-generating material 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.

[0016] 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.

[0017] In some embodiments, this disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-combustible aerosol supply devices. These consumables are sometimes referred to as articles in this disclosure.

[0018] In some embodiments, a non-combustible aerosol supply system, such as its non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, a power source or a heat source. In some embodiments, the heat source includes a carbon substrate, which may be powered to distribute power in the form of heat to aerosol-generating or heat-transferring material adjacent to the heat source.

[0019] 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.

[0020] In some embodiments, consumables for use with non-combustible aerosol supply devices may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transport components, aerosol generators, aerosol generating areas, housings, packaging paper, filters, nozzles, and / or aerosol modifiers.

[0021] An aerosol generating apparatus can receive an article containing aerosol-generating material for heating. In this context, an "article" is a component that includes or contains aerosol-generating material during use, which is heated to atomize the aerosol-generating material, and optionally includes other components during use. A user can insert the article into the aerosol generating apparatus and then heat the article to generate an aerosol, which the user subsequently inhales. The article may, for example, have a predetermined or specific size configured to be placed within a heating chamber of the apparatus sized to receive the article.

[0022] refer to Figure 1The aerosol supply system 10 includes an aerosol supply device 100 for generating aerosols from aerosol-generating materials. The aerosol supply system 10 also includes a replaceable article 110 containing the aerosol-generating materials. Generally, the aerosol-forming device 100 can be used to heat the article 110 to generate an aerosol or other inhalable medium that can be inhaled by a user of the device 100. In this example, the aerosol-forming article 110 is used in conjunction with the aerosol supply device 100. However, in other examples, the aerosol-forming article 110 can be used as an aerosol supply device (e.g., if it is a disposable, one-piece aerosol supply system).

[0023] The aerosol forming apparatus 100 includes a body 102. A housing structure surrounds and houses the various components of the body 102. An article opening 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.

[0024] The device 100 may also include a user-operable control element 150, such as a button or switch, which, when pressed, causes the device 100 to operate. For example, a user can turn on the device 100 by operating the switch 150.

[0025] The aerosol generator 200 is positioned along a longitudinal axis aligned with the axis of the product 110.

[0026] In use, the article 110 can be fully or partially inserted into the aerosol generator 200, where it can be heated by one or more components of the aerosol generator 200.

[0027] Apparatus 100 includes a device for heating aerosol-generating material. The device includes an aerosol-generating assembly, a controller (control circuitry), and a power source. The device forms part of body 102. The aerosol-generating assembly is configured to heat the aerosol-generating material inserted into article 110 through article orifice 104, such that aerosols are generated from the aerosol-generating material. The power source supplies electricity to the aerosol-generating assembly, and the aerosol-generating assembly converts the supplied electrical energy into heat energy for heating the aerosol-generating material. The power source may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries.

[0028] A power source can be electrically connected to the aerosol generating assembly to supply electricity to heat the aerosol-generating material when needed and under the control of a controller. The control circuitry can be configured to enable and disable the aerosol generating assembly based on user input. User input can be achieved by pressing a button or opening a door of the device (e.g., opening a door covering the consumable receiving section). The control circuitry can be configured to enable and disable automatically, for example, when inserting an article.

[0029] Aerosol generating assemblies may include various components that heat aerosol generating materials via an induction heating process. Induction heating is a process of heating a conductive heating element (such as a sensor) through electromagnetic induction. An induction heating assembly may include a sensing element (e.g., one or more induction coils) and means for allowing a changing current (e.g., alternating current) to flow through the sensing element. The changing current in the sensing element generates a changing magnetic field. The changing magnetic field penetrates the sensor (heating element), which is suitably positioned relative to the sensing element, and generates eddy currents within the sensor. The sensor has resistance to the eddy currents, and therefore the flow of the eddy currents overcoming this resistance causes the sensor to be heated by Joule heating. In cases where the sensor contains a ferromagnetic material (such as iron, nickel, or cobalt), heat can also be generated by hysteresis losses in the sensor, i.e., by directional changes in the alignment of magnetic dipoles in the magnetic material with the changing magnetic field. Compared to heating by, for example, conduction, the heat in induction heating is generated within the sensor, thus allowing for rapid heating. Furthermore, no physical contact is required between the sensing element and the sensor, thereby enhancing the freedom of construction and application.

[0030] refer to Figure 2 Article 110 also includes a first substrate 302 and a second substrate 304. The first substrate 302 and the second substrate 304 are each made of paper with a higher weight per square meter (GSM) than aluminum foil backing, such as paper with a weight per square meter (GSM) of 70 to 400 gsm or 100 to 400 gsm, such as paper with a weight per square meter of 240 gsm, or any paper with a GSM greater than 400 gsm. In some embodiments, the paper with a higher GSM than aluminum foil backing can be considered as paper with an even higher GSM than aluminum foil backing. In some embodiments, the paper with a higher GSM can have a thickness of 0.125 mm or 0.35 mm. In other embodiments, the paper with a higher GSM 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 material, for example, a cardboard or paper backing with a metallic side. In other words, the first substrate 302 and / or the second substrate 304 each include an aluminum layer (i.e., a heating layer) and a paper or sheet layer (i.e., a structural layer). In other instances, a layer of another metal or metal alloy may be used instead of the aluminum layer to provide a heating layer for the first substrate 302 and / or the second substrate 304.

[0031] 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 heating layer of the second substrate 304. This means that the first substrate 302 and the second substrate 304 are arranged such that the heating layer is located inside the article 110, while the structural layer is located outside the heating layer, i.e., outside the article 110.

[0032] 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 that spaces the first aerosol generating material 306 and the second aerosol generating material 308 apart. Figure 2 (Not shown in the image). The following will combine... Figures 4A to 4C The at least one intermediate layer is described in more detail. In use, the heating layer, more specifically the aluminum foil, can be induced, for example, by induction, to generate heat, thereby heating the aerosol gel. Heating the aerosol gel generates an aerosol that can be used by a user, for example, by inhalation. The first aerosol generating material 306 and the 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. The article 110 includes a mouthpiece and a distal end opposite the mouthpiece. The mouthpiece is the end from which the user can use / inhale the aerosol. In some embodiments, the article may have a mouthpiece positioned at the mouthpiece. The mouthpiece may be made of a different material than the rest of the article. The mouthpiece may have a different construction than the rest of the article.

[0033] Article 110 is arranged such that the first aerosol generating material 306 and the second aerosol generating material 308 are spaced apart by a gap d. The size of the gap d may affect the airflow velocity and / or pressure in the airflow path during use (e.g., when the user inhales). 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 of heating of the aerosol generating material (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.

[0034] Therefore, if the airflow velocity is not high enough, the airflow may carry insufficient aerosols; for example, aerosol droplets may deposit before reaching 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 generation.

[0035] In this embodiment, the gap d is greater than or equal to 0.9 mm. Advantageously, the inventors have found that a gap d greater than or equal to 0.9 mm can mean a surprisingly large increase in the mass of aerosol delivered to the user, for example, when compared to a system with a gap d less than 0.9 mm. More surprisingly, a gap d greater than or equal to 1.34 mm further enhances this effect. Even more surprisingly, a gap d greater than 1.8 mm (such as substantially equal to 1.84 mm) can result in the generation and / or delivery of a larger mass of aerosol. When the gap d increases beyond 1.84 mm, the mass of delivered aerosol may tend to stabilize or decrease. In some embodiments, the gap 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 the gap d decreases from 4 mm to 1.84 mm, more aerosol can be delivered to the user.

[0036] In this embodiment, the article is elongated. In other embodiments, the article is not elongated; for example, the article may be circular or square. In this embodiment, the article is substantially planar. In other embodiments, the article is not planar. In this embodiment, the first 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, but rather, for example, an aerosol solid or an aerosol liquid. In this embodiment, the aerosol is generated via induction heating. In other embodiments, the aerosol is not generated via induction heating, but is heated by other methods, such as convection or conduction. In this embodiment, the substrate includes components that can be induced to generate heat via induction. In other embodiments, the substrate does not include components that can be induced to generate heat via induction; for example, the substrate may consist only of wood or paper. In this embodiment, the first substrate is the same as the second substrate. In other embodiments, the first substrate is different from the second substrate. In this embodiment, aluminum foil is arranged adjacent to the aerosol-generating material. In other embodiments, the aluminum foil is not arranged adjacent to the aerosol-generating material; for example, a higher 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 higher GSM paper backed by aluminum foil. However, in other embodiments, the first substrate and / or the second substrate is not made of higher GSM paper backed by aluminum foil; for example, the first substrate and / or the second substrate may be made of copper foil or other materials that can generate heat via 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 arrangement of the first substrate and the first aerosol-generating material differs from the arrangement of the second substrate and the second aerosol-generating material.

[0037] refer to Figure 3 The first substrate 302 has an elongated shape and extends longitudinally from the mouth tip to the distal end. A first aerosol-generating material 306 is disposed in a series of discrete first portions 402-410 arranged sequentially along the longitudinal direction. The series of discrete first portions 402-410 are separated from and / or spaced apart from each other. Similarly, the second substrate 304 has an elongated shape extending longitudinally. A second aerosol-generating material 308 is disposed in a series of discrete second portions 412-420 arranged sequentially along the longitudinal direction. In use, the discrete portions of the aerosol-generating material are heated sequentially. For example, each time the user inhales, only one discrete portion is heated to generate an aerosol. However, in other embodiments, multiple discrete portions may be heated to generate an aerosol each time the user inhales.

[0038] In this embodiment, each discrete portion is shaped as a square. In other embodiments, each discrete portion is not shaped as a square; for example, each discrete portion is shaped as a circle or a rhombus. In this embodiment, the discrete portions are identical to each other. In other embodiments, the discrete portions are different from each other. In this embodiment, the discrete first portion is identical to the discrete second portion. In other embodiments, the discrete first portion is different from the discrete second portion; for example, the shape of the discrete second portion may be different from the shape of the discrete first portion. In this embodiment, the first 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 a strip shape or a continuous regular shape or a continuous irregular shape.

[0039] refer to Figure 4A The article 110 includes a first intermediate layer 502. The first intermediate layer 502 has a substantially planar shape and is elongated along a longitudinal direction. The first intermediate layer 502 is configured to connect to a first aerosol generating material 306. The first intermediate layer 502 includes a series of first holes. Each first hole has a shape complementary to a corresponding discrete first portion 402-410. The first intermediate layer 502 is configured to abut against the first aerosol generating material 306 and the first substrate 302, such that each discrete first portion 402-410 fits within the corresponding hole of the first intermediate layer 502.

[0040] In this embodiment, a substantially planar surface may be formed by a first intermediate layer and a first aerosol-generating material extending therethrough. 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.

[0041] 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 adjacent to the second aerosol generating material 308 such that each discrete second portion 412-420 fits within its corresponding second hole. In this way, a substantially planar surface can be formed by the second intermediate layer 504 and the second aerosol generating material 308 extending through it. The thickness of the second intermediate layer 504 is substantially the same as the thickness of the second aerosol generating material 308.

[0042] In this embodiment, a substantially planar surface can be formed by a second intermediate layer and a second aerosol-generating material. 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.

[0043] 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 located at a first end of the third intermediate layer 506 in the longitudinal direction. The pressure drop across article 110 can be important for the user experience. To increase the quality of the aerosol delivered to the user (which is also important for the user experience), it has been found that avoiding obstructions in the airflow path near the aerosol generating material and increasing the outlet area may be beneficial. However, implementing these features may result in an excessively small pressure drop. Therefore, it may be beneficial to change the inlet area to control the pressure drop across article 110.

[0044] The third intermediate layer 506 also includes an outlet opening 510 located at a second end of the third intermediate layer 506 in the longitudinal direction. The first end is opposite to the second end in 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 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 tends to be larger. Furthermore, increasing the area by increasing the width of the outlet opening rather than its thickness helps to more significantly improve aerosol generation.

[0045] 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 spacing and / or gap d between the first aerosol generating material 306 and the second aerosol generating material 308. Therefore, the separation caused by the third intermediate layer 506 results in an airflow path being formed 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 equal to the distance of the gap d. In some embodiments, the size of the gap d is defined not only by the thickness of the adhesive layer used to attach the third intermediate layer 506 to the first intermediate layer 502 and the second intermediate layer 504, but also by the thickness of the third intermediate layer 506. The third intermediate layer 506 includes a bridging member 512 extending across the width of the third intermediate layer 506. The width is defined in a direction perpendicular to both the longitudinal direction and the thickness direction. Reference Figure 4BThe thickness of the bridging element 512 is less than the thickness of the third intermediate layer 506. Advantageously, this means that the bridging element tends not to obstruct the airflow path and / or conduit. In this embodiment, the bridging element is positioned near the bottom surface of the third intermediate layer. In other embodiments, the bridging element is not positioned near the bottom surface; for example, the bridging element may be positioned near the top surface of the third intermediate layer. In some embodiments, the bridging element may be positioned midway between the top and bottom surfaces of the third intermediate layer, i.e., the bridging element is positioned such that the distance between the bridging element and the top surface is equal to the distance between the bridging element and the bottom surface. In some embodiments, the bridging element may be offset from 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 the aerosol-generating material. In some instances, the bridging element may be omitted to provide an airflow path (e.g., dividing the third intermediate layer into two separate pieces).

[0046] 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 aerosol mass carried by the airflow. Specifically, air entering the airflow path can be forced around the flow control feature 514, 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 forces the incoming air into the corner area of ​​the airflow path, thereby improving the mixing effect.

[0047] The flow control feature 514 may also affect the air velocity and / or pressure drop in the airflow path during user inhalation. Without this flow control feature, the air velocity entering the inlet can be significantly higher than the air velocity in the rest of the airflow path when the user inhales. This can also reduce the mixing between the air entering through the inlet and the air in the rest of the airflow path. This means that the article is prone to forming a central air jet, which negatively impacts the performance of the article. Advantageously, the flow control feature helps to reduce and / or mitigate the central air jet formed during user inhalation. Furthermore, the flow control feature helps to improve the mixing between the incoming air through the inlet and the air in the rest of the airflow path.

[0048] 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 helps to reduce the area of ​​the inlet opening. As discussed above, a smaller inlet opening helps to increase the pressure drop in the airflow path. In other words, the flow control feature, when positioned within the inlet opening, can be considered to reduce the area of ​​the inlet opening.

[0049] In this embodiment, the flow control feature is positioned within the inlet opening. In this embodiment, the flow control feature has a T-shaped shape. In other embodiments, the flow control feature does not have a T-shaped shape; for example, it has a cross-shaped, rod-shaped, or cuboid shape. In this embodiment, the flow control feature extends across the entire width of the inlet opening. In other embodiments, the flow control feature does not extend across the entire width of the inlet opening; for example, it extends across a limited portion of the inlet opening.

[0050] In the above embodiments, the thickness of the third intermediate layer defines the size of the gap d. However, in other embodiments, one or more of the thicknesses of the first, second, and third intermediate layers define 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 lasering through one or more intermediate layers.

[0051] Experiments have been conducted on articles with various structures, and these experiments all support the surprising advantages described in this specification. The results obtained from experiments with these articles... Figure 5 , Figure 6A , Figure 6B , Figure 7A , Figure 7B and Figure 9The diagram illustrates this. The artifact used in the experiment is constructed from individual layers. Each layer can be cut using a Silhouette machine, CNC machine tool, or laser cutter. The cut profiles can then be positioned and glued together. The assembled artifact can be tested in the laboratory using Borgwald equipment, repeated 5 times or more, for example, 10 times. For example, Silhouette cutting is generally more reliable and has less variation compared to CNC cutting.

[0052] Figure 5 The amount (mass) of aerosol delivered by airflow to the mouthpiece (where the user can inhale the aerosol) and having different gap sizes d (where the gap size d is the distance between the first aerosol generating material 306 and the second aerosol generating material 308, as referenced above) are shown. Figure 2 A diagram showing the relationship between the various experimental artifacts (described in artifact 110). (See reference) Figure 5 Surprisingly, it can be observed that the amount of aerosol transported by the airflow increases when d = 1.34 mm. Furthermore, it can be seen that a further increase in the gap size d leads to a further increase in the mass of the transported aerosol. From... Figure 5 It can be seen that when d=1.84 mm, more aerosols are transported. As the gap size d increases beyond 1.84 mm, the amount of aerosol generated tends to stabilize.

[0053] Now for reference Figure 6A It shows a graph illustrating the relationship between pressure drop and various inlet areas. Tested to generate... Figure 6A and Figure 6B The products shown in the data are Figure 8 Article A1 in the series has the same structure as 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 opening area is less than 0.4 mm². 2 In the product, a relatively large pressure drop was found, which may adversely affect the performance of the system and / or the user experience. For example, this may result in the user not being able to draw and / or inhale sufficient aerosol from the product. In some embodiments, the area of ​​the inlet opening may be greater than or equal to 0.15 mm². 2 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.

[0054] Now for reference Figure 6B This graph shows the relationship between aerosol delivery volume (mass) and different inlet areas for various articles with different inlet sizes. It should be noted that the articles tested in this graph are... Figure 6A The same products are used in the charts. From Figure 6B As can be seen from the chart, 0.51 mm 2 The inlet area can provide the maximum amount of aerosol delivery. Furthermore, from... Figure 6B It can be seen that as the inlet area increases from 0.51 mm... 2 Reduced to 0.37 mm 2 The aerosol delivery rate also decreased. The applicant also unexpectedly discovered that below 0.5 mm... 2 At that time, the aerosol delivery rate began to decrease from its maximum value. The applicant also unexpectedly discovered that for inlet areas greater than 5 mm²... 2 For the product in question, the resulting aerosol delivery rate decreases from its maximum value. In some embodiments, the area of ​​the inlet opening may be less than or equal to 5 mm². 2 For example, less than or equal to 4 mm 2 Less than or equal to 3 mm 2 For example, less than or equal to 2.61 mm 2 Less than or equal to 1.91 mm 2 Less than or equal to 1.21 mm 2 Less than or equal to 0.86 mm 2 .

[0055] Figure 7A A graph showing the mass of aerosol delivered per intake for various articles with different outlet areas is presented. Table 1 below lists the mass of aerosol delivered per intake. Figure 7A The parameters of various products are drawn in the image.

[0056]

[0057] Table 1

[0058] Figure 7A The structures of the various articles shown are in Figure 8 As shown in the figure: Sub1 – First substrate, on which aerosol gel is deposited; Sub2 – the second substrate, on which aerosol gel is deposited; 1 / 1a / 1b – First intermediate layer; 2 / 2a / 2b – Second intermediate layer; and 3 / 3a / 3b / 3c – Third intermediate layer.

[0059] 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 towards the inlet opening. In these articles, the layer thickness is substantially constant. In these articles, the inlet area is constant.

[0060] from Figure 7A It can be seen that products with larger outlet openings can transport a larger mass of aerosol compared to those with smaller outlet openings. Specifically, compared to... Figure 7A Compared to other products, products A2, A3, and A5 generated the largest amounts of aerosols. Furthermore, from... Figure 7A As can be seen, despite various structural changes in the product, such as different degrees of tapering in the conduit, a larger outlet opening can still lead to an increase in aerosol delivery. This is likely because a larger outlet opening reduces turbulence and / or mixing as the airflow exits the airflow path. Therefore, a larger outlet opening may help reduce the likelihood of aerosols separating from the airflow before being delivered to the user. Furthermore, bends in the airflow path may trap a certain amount of aerosol. A larger outlet opening can help reduce the size of these bends, thereby reducing the amount of aerosol that may be trapped in the airflow path.

[0061] For example, the area of ​​the outlet opening is less than 2.55 mm. 2 Compared to other products, the area is at least 2.55 mm. 2 The outlet opening facilitates the generation and / or delivery of a larger mass of aerosol. Specifically, the area is approximately 6.85 mm². 2 The outlet opening can lead to a significant increase in the amount of aerosol generated and / or delivered to the user. The outlet opening may be defined by the thickness of the third intermediate layer and the adhesive used to bond the third intermediate layer to the first and / or second intermediate layers. Additionally or alternatively, the outlet opening may be defined by the thickness of the first and / or second intermediate layers. In some embodiments, the area of ​​the outlet opening may be greater than or equal to 0.15 mm. 2 For example, greater than or equal to 0.25 mm 2 ≥0.5 mm 2 ≥0.75 mm2 ≥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 or greater 2 5 mm or greater 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 implementations, the area of ​​the outlet opening may be less than or equal to 10 mm². 2 For example, less than or equal to 9 mm 2 or less than or equal to 8 mm 2 or less than or equal to 7 mm 2 or less than or equal to 6 mm 2 or less than or equal to 5 mm 2 or less than or equal to 4.11 mm 2 .

[0062] refer to Figure 7B It shows a graph illustrating the relationship between aerosol delivery volume and the increase in outlet area for various products. Figure 7B All products have the same fixed entrance area. From Figure 7B As can be seen from this, when the export area is increased to greater than 4.11 mm... 2 At that time, the aerosol delivery volume will not change significantly.

[0063] In this implementation and as discussed above, and as... Figure 8In the article shown being tested in the experimental apparatus, the outlet opening and / or inlet opening is rectangular. Therefore, the area of ​​the outlet opening and / or inlet 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 depend 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, perforation, or laser cutting. Advantageously, drilling of the inlet opening can help disperse the inlet gas flow onto the first aerosol generating material and / or the second aerosol generating material. In some embodiments, multiple inlet openings are provided at the distal end. In some embodiments, the inlet opening can have a diameter of substantially 0.88 mm. 2 or 1.76 mm 2 The area. In some embodiments, setting the pressure drop to 70 mmWG to 90 mmWG 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 element is positioned not to cover the first aerosol generating material and the second aerosol generating material. In other embodiments, the bridging element is positioned to at least partially cover the first aerosol-generating material and / or the second aerosol-generating material.

[0064] 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, by achieving a specific pressure drop and / or by achieving a specific quality of aerosol for delivery. An unobstructed airflow path may not require any structures within the airflow path adjacent to the aerosol-generating material. In other words, no object in the airflow path can alter the trajectory of the air flowing in the airflow path near the aerosol-generating material. It should be noted that an unobstructed airflow path embodiment can be consistent with embodiments that include a flow control feature positioned in the inlet and / or a bridging element in the 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 located downstream of the inlet opening. Furthermore, Figure 5 Article A, including the intermediate layer, can also be considered unobstructed because it does not impede the aerosol-generating material. Specifically, since the bridging elements and / or flow control features are offset from and / or do not cover the aerosol-generating material, the flow of the aerosol is not disturbed or altered by the bridging elements and / or flow control features.

[0065] Figure 9 A graph showing the relationship between the mass of the delivered aerosol and various products, obtained through experimental testing on engineered products, is presented. The products may or may not have ribs in the airflow path. Table 2 below lists... Figure 9 The parameters of various products are drawn in the image.

[0066]

[0067] Table 2

[0068] Figure 9 The structures of the various articles shown are in Figure 10 As shown in the figure: Sub 1 – First substrate, on which aerosol gel is deposited; Sub 2 – Second substrate, on which aerosol gel is deposited; 1 / 1a / 1b – First intermediate layer; 2 / 2a / 2b – Second intermediate layer; and 3 / 3a / 3b / 3c – Third intermediate layer.

[0069] 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 towards the inlet opening. Figure 10 The ribs shown in Table 2 can be considered as one or more transverse members that extend across the width of the intermediate layer and / or conduit as discussed above.

[0070] from Figure 9 It can be seen that articles without obstructions generally result in a greater mass of delivered aerosol compared to articles with obstructions. Specifically, articles A9, A10, and A13 show that an unobstructed airflow path allows for the delivery of more aerosol compared to articles with ribs (articles A8, A11, and A12). This further demonstrates that the inlet area allows for adjustment of the pressure drop without significantly affecting other performance factors. In these embodiments, the airflow path is substantially unobstructed. However, in other embodiments, the airflow path is unobstructed.

[0071] 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 through the first intermediate layer 502 to the bottom surface of 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 through the second intermediate layer 504 to the top surface of the second intermediate layer 504.

[0072] 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 fluidly connecting 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 into the channel and / or conduit. The channel and / or conduit can be considered as an airflow path.

[0073] In this embodiment, the channel is composed of a first intermediate layer, a first aerosol generating material, a third intermediate layer, a second intermediate layer, and a second aerosol generating material. In other embodiments, the cavity is not composed of 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 composed of 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.

[0074] The various embodiments described herein are presented merely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of implementation and are not exhaustive and / or exclusive. It should be understood that the advantages, implementations, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or on 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 the embodiments specifically described herein, various embodiments of the invention may suitably include, constitute, or be essentially constituted by suitable combinations of the disclosed elements, components, features, portions, steps, components, etc., or by suitable combinations of the disclosed elements, components, features, portions, steps, components, etc. Furthermore, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. An aerosol-forming article, comprising: The first surface is essentially planar, including materials that generate aerosols; as well as A substantially planar second surface, opposite the first surface, defines an airflow path between the first and second surfaces. Wherein, the airflow path between the first surface and the second surface is unobstructed at the aerosol generating material.

2. The aerosol-forming article according to claim 1, wherein, The first surface includes multiple discrete regions of the aerosol-generating material.

3. The aerosol-forming article according to any of the preceding claims, wherein, The discrete regions are staggered from each other in the longitudinal direction.

4. The aerosol-forming article according to any of the preceding claims, wherein, The airflow path between the first surface and the second surface is free of obstructions in each of the discrete regions.

5. The aerosol-forming article according to any of the preceding claims, wherein, The airflow path between the first and second surfaces spans the entire area of ​​the aerosol-generating material without any obstructions.

6. The aerosol-forming article according to any of the preceding claims, wherein, The airflow path 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.

7. The aerosol-forming article according to any 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 any of the preceding claims, wherein, The layered structure includes at least one intermediate layer, the at least one intermediate layer including a first intermediate layer, wherein the first intermediate layer includes a cut at the aerosol generating material such that the airflow path between the first surface and the second surface is unobstructed at the aerosol generating material.

9. The aerosol-forming article according to any of the preceding claims further includes export.

10. The aerosol-forming article according to claim 9, which is dependent on claim 8, wherein, The outlet is formed in the first intermediate layer.

11. The aerosol forming article according to any of the preceding claims further includes a flow control feature, the flow control feature being positioned such that air from the inlet impacts the flow control feature, the flow control feature being configured to reduce the air velocity.

12. The aerosol-forming article according to claim 11, wherein, The flow control feature is located upstream of the aerosol generating material.

13. An aerosol-forming article according to claim 11 or claim 12, which is dependent on claim 8 or any of its dependent claims, wherein, The flow control feature is formed in the first intermediate layer.

14. The aerosol-forming article according to claim 8 or any dependent claim thereof, wherein, The first intermediate layer includes longitudinally extending spacers, wherein the airflow path is located between the longitudinally extending spacers.

15. The aerosol-forming article according to claim 14, wherein, The longitudinally extending spacer is laterally offset from the aerosol generating material, such that the airflow path between the first surface and the second surface is unobstructed at the aerosol generating material.

16. The aerosol forming article according to any one of claims 1 to 15, further comprising an inlet configured to allow air to flow into the article between the first surface and the second surface.

17. The aerosol-forming article according to any one of claims 1 to 16, further comprising an inlet and an outlet, wherein, The cross-sectional area of ​​at least one of the inlet and the outlet is smaller than the cross-sectional area of ​​the airflow path.

18. The aerosol-forming article according to claim 17, wherein, The minimum cross-sectional area of ​​the airflow path is greater than the cross-sectional area of ​​at least one of the inlet and the outlet.

19. An aerosol supply system, comprising: Aerosol-forming article according to any 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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