Devices, systems, and articles for providing aerosols

Abstract

A system for providing an aerosol from an aerosol generating material, comprising: an inlet (14); an outlet (16); a support structure (28) defining a passageway extending along a longitudinal axis; an aerosol generating material (30) configured to provide, on heating, an aerosol comprising at least one volatile component of the aerosol generating material; a heating device (20) for heating the aerosol generating material, wherein the heating device is configured to heat an air flow that, in use, flows into the system from the inlet (14); and an air director (22) configured to direct the heated air flow into the passageway.

Description

Technical Field

[0001] The present invention relates to an apparatus, system and article for providing aerosols, and more particularly, to articles for use with non-combustible aerosol supply devices. Background Technology

[0002] Smoking consumables such as cigarettes and cigars burn tobacco during use to produce tobacco smoke. Alternatives to these types of consumables release compounds from the base material through heating rather than combustion, thereby releasing an inhalable aerosol or mist. These consumables can be referred to as non-combustible smoking consumables or aerosol generating components.

[0003] One example of such products is a heating device that releases compounds by heating rather than burning a solid aerosol-generating material. In some cases, this solid aerosol-generating material may contain tobacco material. The heating process causes at least one component of the material to volatilize, typically forming an inhalable aerosol. These products may be referred to as heated non-combustible devices, tobacco heating devices, or tobacco heating products. A variety of different devices are known for volatilizing at least one component of a solid aerosol-generating material. Summary of the Invention

[0004] In one aspect, an article (e.g., a non-combustible article) for providing an aerosol is provided. The article includes an inlet (e.g., an article inlet), an outlet (e.g., an article outlet), a support structure defining a channel, and an aerosol-generating material. The aerosol-generating material is configured to provide an aerosol comprising at least one volatile component of the aerosol-generating material upon heating. The aerosol-generating material includes sides arranged to be exposed to an airflow passing through the channel.

[0005] In another aspect, an article (e.g., a non-combustible article) for providing an aerosol is provided. The article includes an inlet (e.g., an article inlet), an outlet (e.g., an article outlet), a support structure defining a channel, and an aerosol-generating material. The aerosol-generating material is configured to provide an aerosol comprising at least one volatile component of the aerosol-generating material upon heating. At least a portion of the aerosol-generating material is suspended within the channel (e.g., as defined below), optionally such that both sides of said at least a portion of the aerosol-generating material are arranged to be exposed to an airflow through the channel.

[0006] In another aspect, an apparatus (e.g., a non-combustible aerosol supply device) is provided for providing aerosols from an aerosol-generating article. The apparatus includes an inlet (e.g., an apparatus inlet), a region for receiving aerosol-generating material or a volume thereof, and a heating device for heating the aerosol-generating material or the volume thereof. The apparatus may include a support structure arranged to support the aerosol-generating material (e.g., arranged to hold / suspend the aerosol-generating material within / across a channel). The heating device may be configured to heat an airflow flowing into the system from the inlet during use when a user performs a draw action at an outlet (e.g., an apparatus outlet or an article outlet). The aerosol-generating material may be included in an article for providing the aerosol (e.g., an article including a channel in which the aerosol-generating material is held / suspended).

[0007] In another aspect, a system is provided for providing aerosols from an aerosol-generating material (e.g., a non-combustible aerosol supply system). The system includes an inlet (e.g., a device inlet), an outlet (e.g., a device outlet or article outlet) through which a user can perform a suction action, a support structure defining a channel (e.g., one or more inner walls defining the channel), an aerosol-generating material, and a heating device for heating the aerosol-generating material. The aerosol-generating material is configured to provide an aerosol comprising at least one volatile component of the aerosol-generating material when heated. The aerosol-generating material includes both sides arranged to be exposed to an airflow passing through the channel. The heating device may be configured to heat the airflow flowing into the system from the inlet during use when a user performs a suction action at the outlet. The aerosol-generating material may be included in an article for providing the aerosol (e.g., an article including the support structure and / or the channel).

[0008] In another aspect, an article for providing an aerosol is provided. The article includes an inlet (e.g., an article inlet), an outlet (e.g., an article outlet), a support structure (e.g., one or more walls defining a tubular channel) defining a channel extending from the inlet along a channel axis to the outlet, and a volume of aerosol-generating material configured to provide an aerosol comprising at least one volatile component of the aerosol-generating material upon heating. The volume of aerosol-generating material is arranged within the channel and includes a helical aerosol-generating material (also referred to as a helical structure). The helical structure extends radially from a helical axis. The helical axis is parallel to the channel axis.

[0009] In another aspect, a system is provided for providing an aerosol from an aerosol-generating material. The system includes: an inlet (e.g., a device inlet); an outlet (e.g., a device outlet or article outlet); a support structure (e.g., one or more inner walls defining a channel) defining a channel extending from the inlet along a channel axis to the outlet; a flow deflector arranged to guide a heated airflow into the channel (e.g., a flow deflector included in a device or in an article containing the aerosol-generating material); a volume of aerosol-generating material configured to provide an aerosol containing at least one volatile component of the aerosol-generating material upon heating; and a heating device for heating the volume of aerosol-generating material. The volume of aerosol-generating material is arranged within the channel and includes a spiral aerosol-generating material (also referred to as a spiral structure). The spiral structure extends radially from a spiral axis parallel to the channel axis. The heating device is configured to heat the airflow flowing into the system from the inlet during use when a user performs a suction action at the outlet. The spiral aerosol-generating material may be included in an article for providing the aerosol (e.g., an article including a support structure and / or a channel).

[0010] The following optional features may be applied individually or in any suitable combination to any of the above aspects or implementations.

[0011] Any reference to “aerosol generating material” in this article may be replaced with “aerosol generating membrane” (although in some cases we choose to explicitly refer to membrane, this should not be interpreted as the material being disclosed only as a membrane in those cases).

[0012] The channel may extend along a longitudinal axis. At least a portion of the aerosol-generating material is suspended across the channel, or may be suspended across the channel. The aerosol-generating material may be suspended across the channel such that at least a portion of the aerosol-generating material is arranged on both sides to be exposed to the airflow passing through the channel. The aerosol-generating material may be suspended across the channel such that the surface of the aerosol-generating material is arranged substantially parallel to the longitudinal axis.

[0013] The aerosol-generating material may have a longitudinal axis. This longitudinal axis may be along the principal dimension of the aerosol-generating material (e.g., the aerosol-generating material may be substantially two-dimensional and have a principal or longer dimension or length and a secondary or shorter dimension or length, with the longitudinal axis defined along the longer dimension or length). The channel may have a longitudinal axis along the principal dimension of the channel (e.g., along the length of the channel). The longitudinal axis of the aerosol-generating material may be parallel to the longitudinal axis of the channel.

[0014] Aerosol-generating materials can be planar or essentially two-dimensional.

[0015] Aerosol generating materials may include or be configured as aerosol generating membranes.

[0016] Aerosol-generating materials (e.g., membranes) can be sheet-like materials.

[0017] The channel can be essentially cylindrical.

[0018] The passage can be straight or curved.

[0019] The aerosol generating material can intersect with the flow path from inlet to outlet. This flow path can be an airflow as described above, that is, the airflow that flows into the system from the inlet when the user performs a suction action at the outlet during use.

[0020] The sides arranged to be exposed to the airflow through the channel may include opposing surfaces of the aerosol-generating material (e.g., front and rear surfaces, or upper and lower surfaces). For example, these two opposing surfaces may correspond to opposite sides of an aerosol-generating material sheet (e.g., the aerosol-generating material may be a sheet or film as described above and elsewhere herein).

[0021] A first airflow path may be disposed within the channel on a first side of the aerosol-generating material, and a second airflow path may be disposed within the channel on a second side of the aerosol-generating material. The first and second airflow paths may be fluid-separated, meaning that air cannot flow from one path to the other while traveling along either the first or second path (e.g., at an intermediate location). Alternatively, the channel and material may be configured to allow air to flow from one path to the other while traveling along either the first or second airflow path, for example, through pores in the material or using a permeable material.

[0022] Aerosol-generating materials can be disposed on or within a matrix. The matrix can be porous. Aerosol-generating materials can permeate (impregnate, wet, penetrate, or penetrate) the matrix. Aerosol-generating materials can also be impermeable to the matrix (e.g., aerosol-generating materials can have a matrix (e.g., paper) core).

[0023] The substrate may include paper. The substrate may include cardboard. The substrate may include thin paper. The substrate may include a mesh structure (e.g., a metal mesh). The mesh structure may contain sensing material (e.g., the mesh structure may act as a sensor for inductive heating).

[0024] Alternatively, the aerosol-generating material may be matrix-free (e.g., disposed and / or suspended without a supporting matrix layer (e.g., the matrix defined above)). The article may consist only of the aerosol-generating material disposed across the channel (e.g., suspended as defined above).

[0025] The channel can have a width or diameter less than 12 mm. The channel can have a width or diameter less than 10 mm. The channel can have a width or diameter between 4 mm and 10 mm. The channel can have a width or diameter between 8 mm and 10 mm. The channel can have a width or diameter between 6 mm and 8 mm. The channel can have a width or diameter between 4 mm and 6 mm.

[0026] The channel may include an aerosol generation section. The aerosol generation section may include aerosol-generating materials. The aerosol generation section may have a pressure drop between 0 mm Wg and 80 mm Wg (0 Pa – 785 Pa). The aerosol generation section may have a pressure drop less than 60 mm Wg (588 Pa). The aerosol generation section may have a pressure drop between 20 mm Wg and 60 mm Wg (196 Pa – 588 Pa). The aerosol generation section may have a pressure drop less than 20 mm Wg (196 Pa).

[0027] The pressure drop from the area for receiving aerosol generation material to the outlet (e.g., the pressure drop across the article from the article inlet to the article outlet) can be between 30 mm Wg and 95 mm Wg (294 Pa – 932 Pa). The pressure drop from the area for receiving aerosol generation material to the outlet (e.g., from the article inlet to the article outlet 46) can be between 40 mm Wg and 70 mm Wg (392 Pa – 686 Pa).

[0028] The channel or aerosol generation section can have a length of less than 100 mm (e.g., axial length along the airflow direction). The channel or aerosol generation section can have a length of less than 80 mm. The channel or aerosol generation section can have a length between 20 mm and 80 mm. The channel or aerosol generation section can have a length between 20 mm and 60 mm. The channel or aerosol generation section can have a length between 30 mm and 40 mm.

[0029] The product may include a filter plug.

[0030] The article may include a tubular region (e.g., a first tubular region, a hollow or internal tubular region, or a heat exchange tube or sleeve). The tubular region may be arranged between the channel (e.g., having an aerosol-generating material) and the filter plug.

[0031] The product may include a second tubular region or a nozzle end tube.

[0032] The article may have the same width or diameter as the channel (e.g., the channel may be defined by the wall or packaging paper of the consumable article). The article may have a width or diameter less than 12 mm. The article may have a width or diameter less than 10 mm. The article may have a width or diameter between 4 mm and 10 mm. The article may have a width or diameter between 8 mm and 10 mm. The article may have a width or diameter between 6 mm and 8 mm. The article may have a width or diameter between 4 mm and 6 mm.

[0033] The length of the article (e.g., including the length of each of the channel / aerosol generation section, the filter plug (if present), the tubular region (if present), and the nozzle tube (if present)) may be less than 100 mm. The length of the article may be less than 80 mm. The length of the article may be between 50 mm and 80 mm. The length of the article may be between 70 mm and 80 mm.

[0034] The perimeter of the product can be less than 30 mm. The perimeter of the product can be between 23 mm and 25 mm. The perimeter of the product can be 25 mm. The perimeter of the product can be between 22 mm and 23 mm. The perimeter of the product can be between 19 mm and 22 mm. The perimeter of the product can be between 16 mm and 19 mm. The perimeter of the product can be less than 16 mm.

[0035] Aerosol-generating materials can have a thickness of less than 2 mm. Aerosol-generating materials can have a thickness of less than 1 mm. Aerosol-generating materials can have a thickness of less than 0.5 mm. Aerosol-generating materials can have a thickness of less than 0.1 mm.

[0036] One or more structures (e.g., having or being formed by a flow deflector, such as one or more nozzles) may be provided for guiding the heated airflow (e.g., the article or system may include such structures). The flow deflector may be configured to guide the heated airflow into a channel.

[0037] The air deflector can be configured to selectively guide the heated airflow into the channel in multiple different directions or to various locations within the channel (e.g., multiple different locations along the channel width or circumference).

[0038] The flow deflector can be movable (e.g., tiltable or rotatable).

[0039] A movable baffle may be provided (e.g., formed as part of or included as part of a guide structure). The movable baffle may be configured to selectively block the heated airflow from entering the channel, or to guide the heated airflow to one or more of a plurality of different locations in the channel along the channel width or circumference.

[0040] A sensor can be set up and configured to detect when a user performs a suction action at the outlet. The sensor can be a flow or pressure sensor (e.g., a microphone or suction sensor).

[0041] A temperature sensor can be set, and the temperature sensor can be configured to measure the temperature of the heated airflow.

[0042] The system can be configured to increase the temperature of the heating device after detecting that the user has performed a suction action at the outlet. The system can also be configured to increase the temperature of the heating device from a first temperature to a second temperature after detecting that the user has performed a suction action at the outlet. After the first temperature increase, the system can be configured to further increase the temperature of the heating device from the second temperature to a third temperature after detecting that the user has performed a further suction action at the outlet.

[0043] Aerosol-generating materials (e.g., membranes) may include perforations. The size of the perforations can vary. The size of the perforations may, for example, gradually increase along the length of the article. The length may be parallel to the longitudinal axis of the channel.

[0044] Multiple layers of aerosol-generating materials (e.g., membrane layers, each of which can be an individual aerosol-generating membrane) can be configured. Each layer can be spaced apart from adjacent layers. The surface of each layer can be arranged parallel to the longitudinal axis.

[0045] The aerosol generating material may include a first layer (e.g., a membrane) of a plurality of layers. Each layer (e.g., each aerosol generating membrane) may be disposed across the channel (e.g., suspended as defined above) such that each layer intersects the channel in the axial direction or is parallel to the channel in the axial direction (e.g., the longitudinal axis of the channel).

[0046] The spacing between layers can be between 10 micrometers and 10 mm. The spacing between layers can be between 10 micrometers and 1.5 mm. The spacing between layers can be between 0.1 mm and 1 mm. The spacing between layers can be between 1 mm and 3 mm. The spacing between layers can be between 1 mm and 2 mm. The spacing between layers can be between 0.5 mm and 1.5 mm. This spacing can be less than 0.5 mm.

[0047] Each layer (e.g., each aerosol-generating membrane) may have a thickness of less than 2 mm. Each layer (e.g., each aerosol-generating membrane) may have a thickness of less than 1 mm. Each layer (e.g., each aerosol-generating membrane) may have a thickness of less than 0.5 mm. Each layer (e.g., each aerosol-generating membrane) may have a thickness of less than 0.1 mm.

[0048] Alternatively, aerosol generating materials may consist of only one layer (e.g., a single aerosol generating membrane).

[0049] Each aerosol generating material layer (e.g., a membrane) (or each group of aerosol generating material layers / membranes) can be aligned with a corresponding flow deflector, or with a corresponding position of a variable flow deflector (e.g., the flow deflector described above).

[0050] One layer (e.g., a membrane) of an aerosol-generating material may be separated from an adjacent layer (e.g., a membrane) by a separator, for example. This separator may be permeable. The separator may be perforated.

[0051] Alternatively, the separator can be airtight.

[0052] Multiple layers (e.g., membranes) can be offset axially (e.g., relative to the longitudinal axis of the channel), such that some layers (e.g., membranes) are positioned closer to the inlet than others (e.g., closer to the inlet / closer to the upstream in terms of fluid flow).

[0053] The channel may include a width perpendicular to an axis (e.g., a longitudinal axis), which is defined between the two sides of the channel. Multiple layers (e.g., membranes) may be distributed along the width. The multiple layers (e.g., membranes) may be positioned closer to the inlet (approaching the middle of the width).

[0054] A portion of the first layer (e.g., a portion of the first membrane) of a plurality of layers may be offset axially relative to a portion of the second layer (e.g., a portion of the second membrane) of a plurality of layers.

[0055] The channel can be a first channel, and the aerosol generating material can be a first aerosol generating material (e.g., a first set of multiple layers / films). A second channel can be provided, and a second aerosol generating material or a second set of multiple layers (e.g., a film) thereof can be suspended across the second channel (e.g., as defined above). The second aerosol generating material or its layers can be positioned in the same manner as described above with respect to the first aerosol generating material or its layers (within the second channel).

[0056] Aerosol-generating materials (e.g., membranes) can be helical. In other words, aerosol-generating materials (e.g., membranes) can be configured or otherwise formed into helical aerosol-generating materials (e.g., membranes).

[0057] The helical structure can be supported on a frame. The frame can be configured to hold the aerosol-generating material (e.g., a membrane) in a helical shape, and / or configured to maintain the shape of the helical structure.

[0058] The helical structure can be supported or suspended between a pair of supports positioned at opposite ends (e.g., axial ends) of the helical structure. Each of the pair of supports can be porous. One of the pair of supports can include a mesh material. An aerosol-generating material (e.g., a membrane) can be disposed on the helical mesh structure (e.g., coated or suspended on a mesh structure arranged or formed in a helical shape, such as a metal mesh).

[0059] A certain volume of aerosol generating material (e.g., a membrane) can be set, which includes multiple helical aerosol generating materials (e.g., membranes).

[0060] The support structure may define multiple channels, and each corresponding channel may contain a corresponding aerosol-generating material (e.g., a membrane). Each corresponding aerosol-generating material (e.g., a membrane) may include a corresponding helical aerosol-generating material (e.g., a membrane). A flow deflector (e.g., a flow deflector as described above) may be configured to selectively guide the heated airflow into one or more of these channels.

[0061] The implementation will now be described by way of example only, with reference to the accompanying drawings. Attached Figure Description

[0062] Figure 1 A schematic diagram of an exemplary non-combustible aerosol supply system is shown.

[0063] Figure 2 A schematic diagram of an exemplary non-combustible aerosol supply system is shown.

[0064] Figure 3 An exemplary variable airflow guide device is shown.

[0065] Figure 4 An exemplary variable airflow guide device is shown.

[0066] Figure 5 An exemplary variable airflow guide device is shown.

[0067] Figure 6A A schematic arrangement of consumables including aerosol-generating materials is shown in an area for receiving aerosol-generating materials.

[0068] Figure 6B A schematic arrangement of consumables including aerosol-generating materials is shown in an area for receiving aerosol-generating materials.

[0069] Figure 7A An exemplary consumable including aerosol-generating materials is shown.

[0070] Figure 7B An exemplary consumable including aerosol-generating materials is shown.

[0071] Figure 8A A perspective view of an exemplary consumable article including aerosol-generating materials is shown.

[0072] Figure 8B It shows Figure 8A A side view of an exemplary consumable article including aerosol-generating materials.

[0073] Figure 9 A side view of an exemplary consumable article including aerosol-generating materials is shown.

[0074] Figure 10 A cross-sectional view of an exemplary consumable article including aerosol-generating materials is shown.

[0075] Figure 11 A cross-sectional view of an exemplary consumable article including aerosol-generating materials is shown.

[0076] Figure 12A A cross-sectional view of an exemplary consumable article including aerosol-generating materials is shown.

[0077] Figure 12B A cross-sectional view of an exemplary consumable article including aerosol-generating materials is shown.

[0078] Figure 13A A cross-sectional view of an exemplary consumable article including aerosol-generating materials is shown.

[0079] Figure 13B A cross-sectional view of an exemplary consumable article including aerosol-generating materials is shown.

[0080] Figure 13C A cross-sectional view of an exemplary consumable article including aerosol-generating materials is shown.

[0081] Figures 14A to 14D Cross-sectional views of an exemplary consumable article including aerosol-generating materials are shown before and during use.

[0082] Figure 15 A perspective view of an exemplary aerosol-generating material is shown.

[0083] Figure 16 The graphs show the in-feed suction performance of the aerosol generating material under constant operating temperature and increasing operating temperature curves. Detailed Implementation

[0084] As used herein, the term "delivery system" is intended to cover a system for delivering at least one substance to a user, and includes: Combustion-type aerosol supply systems, such as cigarettes, cigarettes, cigars, and tobacco for pipes or for self-rolled or self-made cigarettes (based on or not based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokeable materials); Non-combustible aerosol supply systems that release compounds from aerosol-generating materials without combustion, such as electronic cigarettes, heated tobacco products, and mixing systems, to generate aerosols using combinations of aerosol-generating materials; and An aerosol-free delivery system delivers at least one substance to a user via mouth, nose, skin, or other means without forming an aerosol. This includes, but is not limited to, tablets, chewing gum, patches, articles including inhalable powders, and oral products (such as oral tobacco including snuff or wet snuff), wherein the at least one substance may or may not include nicotine.

[0085] According to this disclosure, a "non-combustible" aerosol delivery system is an aerosol delivery system in which the aerosol generating material, comprising the aerosol delivery system (or its components), delivers at least one substance to a user without combustion or ignition. In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system. In some embodiments, the non-combustible aerosol delivery 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 essential.

[0086] 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.

[0087] 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 may be in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the mixing system includes liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0088] 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.

[0089] 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.

[0090] 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 matrix, which may be powered to distribute power in the form of heat to aerosol-generating or heat-transferring materials near the heat source.

[0091] In some embodiments, a non-combustible aerosol supply system may include a region for receiving aerosol generating materials (e.g., as a consumable article or included in a consumable article), an aerosol generator, an aerosol generating region, a housing, a nozzle, a filter, and / or an aerosol modifier.

[0092] An aerosol generator is a device configured to generate aerosols from aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, causing the material to release one or more volatiles to form an aerosol.

[0093] 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 transport component, aerosol generator, aerosol generating area, housing, packaging paper, filter, nozzle, and / or aerosol modifier.

[0094] Aerosol-generating materials are materials that can generate aerosols, for example, when heated, irradiated, or energized in any other way. Aerosol-generating materials may be in solid, liquid, or semi-solid (gel) form, and may or may not contain active substances and / or fragrances.

[0095] 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.

[0096] The aerosol-generating material may contain a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a substance to be transported and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. Specifically, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0097] Aerosol generating materials may include or be configured as aerosol generating membranes. As noted above, any reference to “aerosol generating materials” in this document may be replaced by “aerosol generating membrane” (although in some cases we may choose to explicitly refer to membranes, this should not be construed as the material being disclosed only as a membrane in those cases).

[0098] Aerosol-generating materials may include binders, such as gelling agents, and aerosol-forming agents. Optionally, a substance to be transported and / or fillers may also be present. Aerosol-generating materials may be substantially free of plant material. Specifically, in some embodiments, aerosol-generating materials are substantially free of tobacco.

[0099] The aerosol-generating material can have a thickness of about 0.015 mm to about 1 mm. For example, the thickness can be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

[0100] Aerosol generating materials may include more than one layer of aerosol generating material (e.g., a membrane), and the thickness described herein may refer to the total thickness of those layers (e.g., the membrane).

[0101] Aerosol-generating materials can be continuous. For example, aerosol-generating materials can include or be continuous sheets of material (e.g., continuous film sheets). The sheets can be in the form of packaging paper, which can be aggregated to form aggregated sheets, or they can be shredded to form shredded materials. Shredded materials can include one or more strands or one or more strips of aerosol-generating material.

[0102] The aerosol-generating material can be discontinuous. For example, the aerosol-generating material can include one or more discrete portions or regions of aerosol-generating material, such as dots, strips, or lines, which can be supported on a support. In these embodiments, the support can be planar or non-planar.

[0103] Aerosol generating materials may include or may be "amorphous solids". In some embodiments, the aerosol generating material is configured as an amorphous solid aerosol generating membrane. The amorphous solid may be a "monolithic solid". The amorphous solid may be substantially non-fibrous. 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 amorphous solid may, for example, include from about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of amorphous solids.

[0104] Amorphous solids may be substantially free of plant material. Amorphous solids may be substantially free of tobacco.

[0105] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers and / or antioxidants.

[0106] The material may be present on or within the support to form a matrix. The support may be, for example, paper, cardboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support includes a receptor. In some embodiments, the receptor is embedded within the material. In some alternative embodiments, the receptor is located on one or both sides of the material.

[0107] Consumables are articles that include or consist of aerosol-generating materials, some or all of which are intended to be consumed by the user during use. Consumables may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, packaging paper, a nozzle, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to generate an aerosol. The heater may, for example, include a combustible material, a material that can be heated by electrical conduction, or a sensor.

[0108] Aerosol generating materials can be formed by mixing a binder (such as a gelling agent) with a solvent (such as water), an aerosol forming agent, and one or more other components (such as one or more substances to be transported) to form a slurry, and then heating the slurry to evaporate at least some of the solvent to form an aerosol generating material.

[0109] In some embodiments, the aerosol-generating material includes: - 1 wt% - 80 wt% of adhesive; and / or - 5 wt%-80 wt% aerosol forming agent; and - Optionally, active substances and / or flavoring agents; All of these weights are calculated based on dry weight.

[0110] In some cases, the preparation of an aerosol generating material may include: (a) forming a slurry comprising the components of the aerosol generating material, (b) forming a slurry layer, (c) optionally, curing the slurry to form a gel, and (d) drying the gel to form the aerosol generating material.

[0111] Step (b) of forming the slurry layer may include, for example, spraying, casting, or extruding the slurry. In some cases, the slurry layer is formed by electro-spraying the slurry. In some cases, the slurry layer is formed by casting the slurry.

[0112] In some cases, steps (b) and / or steps (c) and / or steps (d) may occur at least partially simultaneously (e.g., during electrospraying). In some cases, these steps may occur sequentially.

[0113] Step (b) may include forming a slurry layer on the carrier.

[0114] Step (c) of curing the gel may include adding a curing agent to the slurry. For example, the slurry may contain sodium alginate, potassium alginate, or ammonium alginate as a binder, and a curing agent containing a calcium source (such as calcium chloride) may be added to the slurry to form a calcium alginate gel.

[0115] During step (d), the slurry may be heated to remove solvent, for example to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of solvent.

[0116] In some cases, the slurry solvent may consist essentially of water, or be composed of water alone. In other cases, the slurry may contain approximately 50 wt%, 60 wt%, 70 wt%, 80 wt%, or 90 wt% of solvent (WWB).

[0117] In some embodiments, the binder comprises a hydrocolloid. In some embodiments, the binder comprises one or more compounds selected from the group consisting of: alginate, pectin, starch (and derivatives), cellulose (and derivatives), gum, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and / or pectin and may be mixed with a curing agent (such as a calcium source) during the formation of the aerosol-generating material. In some cases, the aerosol-generating material may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0118] In some embodiments, the binder comprises alginate, and the amount of alginate in the amorphous solid is 10 wt%-30 wt% of the amorphous solid (calculated on a dry weight basis). In some embodiments, alginate is the only binder present in the amorphous solid. In other embodiments, the binder comprises alginate and at least one other binder, such as gum.

[0119] In some embodiments, the binder comprises a mixture of alginate and carboxymethyl cellulose (CMC). Suitably, the binder contains a greater amount of CMC than alginate; for example, in some cases, the ratio of CMC to alginate is about 5:1, about 3:1, about 2:1, or about 1.5:1; for example, in the range of 5:1 to 1.5:1.

[0120] In some embodiments, the amorphous solid may contain a binder containing carrageenan.

[0121] As used herein, the terms "aerosol forming agent" or "aerosol generating agent" refer to agents that promote the formation of aerosols. Aerosol forming agents can promote aerosol formation by inducing the initial atomization and / or condensation of gases into inhalable solid and / or liquid aerosols.

[0122] In some embodiments, the aerosol forming agent may comprise one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl octanoate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenylacetate, glyceryl tribocate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0123] In embodiments where the amorphous solids contain flavoring agents, suitably, the amorphous solids contain up to about 60 wt%, 50 wt%, 40 wt%, 30 wt%, 20 wt%, 10 wt%, or 5 wt% of flavoring agent. In some cases, the amorphous solids may contain at least about 0.5 wt%, 1 wt%, 2 wt%, 5 wt%, 10 wt%, 20 wt%, or 30 wt% of flavoring agent (all on a dry weight basis). For example, the amorphous solids may contain 0.1 wt%-60 wt%, 1 wt%-60 wt%, 5 wt%-60 wt%, 10 wt%-60 wt%, 20 wt%-50 wt%, or 30 wt%-40 wt% of flavoring agent. In some cases, the flavoring agent (if present) comprises menthol, is substantially composed of menthol, or is composed of menthol. In some cases, the amorphous solids do not contain flavoring agents.

[0124] As used herein, "active substance" can refer to a physiologically active material, which is a material intended to achieve or enhance a physiological response. Active substances can be, for example, selected from nutritional supplements, nootropics, and psychoactive substances. Active substances can be naturally occurring or synthetically obtained. Active substances may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (such as B6 or B12 or C), melatonin, or components, derivatives, or combinations thereof. Active substances may include one or more components, derivatives, or extracts of tobacco or other plants.

[0125] In some embodiments, the active ingredient includes nicotine. In some embodiments, the active ingredient includes caffeine, melatonin, or vitamin B12.

[0126] As used herein, the terms “flavoring agent” and “flavoring” refer to materials that, where permitted by local regulations, can be used in products to produce the taste, aroma, or other bodily sensation desired by an adult consumer. These can include naturally occurring flavoring materials, plants, plant extracts, synthetic materials, or combinations thereof (e.g., tobacco, licorice (licorice extract), hydrangea, eugenol, Japanese magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, holly, cherry, berries, raspberries, cranberries, peach, apple, orange, mango, citrus, lemon, lime, tropical fruits, papaya, rhubarb). Grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Tolingo, bourbon whiskey, Scotch whiskey, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, bitter bean husk, nutmeg, sandalwood, bergamot, geranium, arabesque tea, sorghum, areca leaf, coriander, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cinnamon, caraway, cognac, jasmine, ylang-ylang, sage. Herbs, fennel, mustard, green bell pepper, ginger, coriander, coffee, peppermint oil from any kind of mint, eucalyptus, star anise, cocoa, lemongrass, red beans, flax, ginkgo leaves, hazelnuts, hibiscus, bay leaves, yerba mate, orange peel, rose, tea (such as green or black tea), thyme, juniper, elderberry, basil, bay leaves, cumin, oregano, chili peppers, rosemary, saffron, lemon peel, mint, perilla, turmeric, coriander, myrtle, blackcurrant, valerian, Spanish bell pepper, dried nutmeg, and more. Meadows, marjoram, olives, lemon balm, lemon basil, scallions, parsley, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclosulfonates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plants, or breath fresheners. They can be imitation, synthetic, or natural ingredients or mixtures thereof. They can be in any suitable form, such as liquids like oils, solids like powders, or gases.

[0127] The flavoring agent may suitably include one or more mint flavors, suitably peppermint oil from any species of the genus *Mentha*. The flavoring agent may suitably include menthol, consist essentially of menthol, or consist of menthol. In some embodiments, the flavoring agent includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent includes flavor components of cucumber, blueberry, citrus fruits, and / or cranberries. In some embodiments, the flavoring agent includes eugenol. In some embodiments, the flavoring agent includes flavor components extracted from tobacco.

[0128] In some embodiments, in addition to or in place of aromatactic or gustatory nerves, flavoring agents may also include sensory agents designed to achieve somatic sensations typically induced and perceived by chemical stimulation of the fifth cranial nerve (trigeminal nerve), and these may include agents that provide heating, cooling, tingling, or numbing effects. Suitable thermal agents may be, but are not limited to, vanillyl ether, and suitable coolants may be, but are not limited to, eucalyptol, WS-3.

[0129] Active substances and / or flavoring agents may include tobacco materials.

[0130] As used herein, the term "tobacco material" means any material that includes tobacco or its derivatives. The term "tobacco material" can include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material can include one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extracts.

[0131] The tobacco used to produce tobacco materials can be any suitable tobacco, such as single-grade or blended tobacco, shredded or whole-leaf tobacco, including Virginia tobacco and / or Burley tobacco and / or Oriental tobacco. It can also be tobacco particle "powder" or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as rolled shredded stems. The tobacco material can be ground tobacco or reconstituted tobacco material. Reconstituted tobacco material can include tobacco fibers and can be formed by casting, by a method based on a wire-paper type with the subsequent addition of tobacco extracts, or by extrusion.

[0132] Active substances and / or flavorings may include or be derived from one or more plants or their components, derivatives or extracts.

[0133] As used herein, the term "plant" includes any material derived from plants, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, pods, etc. Alternatively, the material may include naturally occurring active compounds found in plants, obtained through synthesis. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, fine particles, pellets, fragments, strips, flakes, etc.

[0134] Examples of plants include tobacco, eucalyptus, star anise, cocoa, fennel, lemongrass, peppermint, spearmint, red tea tree, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice (licorice extract), matcha, yerba mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, clove, cinnamon, coffee, anise, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, red pepper, rosemary, saffron, and lavender. Grass, lemon peel, mint, juniper, elderberry, vanilla, holly, perilla, turmeric, turmeric root powder, sandalwood, coriander leaves, bergamot, orange blossom, myrtle, blackcurrant, valerian, Spanish bell pepper, dried nutmeg, damarin, marjoram, olive, lemon mint, lemon basil, chives, parsley, verbena, tarragon, geranium, mulberry, ginseng, theanine, tetramethyluric acid, maca, Indian ginseng, dami, guana tea, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: wild mint, mint CV, Egyptian mint, peppermint, basil mint CV, peppermint CV, spearmint, heartleaf spearmint, longleaf mint, pineapple mint, lip mint, spearmint CV, and apple mint.

[0135] In some embodiments, the plant is selected from eucalyptus, star anise, and cocoa. In some embodiments, the plant is selected from red tea tree and fennel.

[0136] refer to Figure 1 and Figure 2 A non-combustible aerosol supply system or its non-combustible aerosol supply device 1 typically includes electronic components 12, such as a power source and a controller. The electronic components 12 may include sensors configured to detect when a user performs a suction action at the outlet. The electronic components 12 may include a suction sensor (e.g., a microphone or pressure sensor). The power source may be a power source such as a battery. The non-combustible aerosol supply system or non-combustible aerosol supply device includes a housing 10, an inlet 14, an aerosol generator 20, a region 24 for receiving aerosol-generated material, and an outlet 16. Of course, the arrangement and layout of these features can vary between different systems. Figure 1 This is just one example. For example, outlet 16 may be formed in nozzle 18, or nozzle 18 may be omitted. For example, outlet 16 may be formed in consumable article 34.

[0137] As noted above, any reference to “aerosol generating material” in this article may be replaced with “aerosol generating membrane” (although in some cases we choose to explicitly refer to membrane, this should not be interpreted as the material being disclosed only as a membrane in those cases).

[0138] An airflow path is provided from inlet 14 to outlet 16. This airflow path is typically arranged to pass through a region 24 located between inlet 14 and outlet 16 for receiving aerosol-generating material. Outlet 16 may be arranged to allow a user to perform a suction action thereon, so that air is drawn in through inlet 14 and passes through region 24 for receiving aerosol-generating material.

[0139] The aerosol generator 20 may include a heating device, such as a convection heating system, which includes, for example, a heater or heating element. The heating device may be configured or arranged to heat the airflow drawn in through inlet 14. For example, a heater may be arranged in the airflow path between inlet 14 and the region 24 for receiving aerosol-generating material. The heater may heat the airflow drawn into the device 1 such that the hot airflow or heated airflow flows to (e.g., drawn in by a user) the region 24 for receiving aerosol-generating material. Providing a hot airflow or heated airflow to the region 24 for receiving aerosol-generating material may generally be referred to as providing convection heating to the region 24 for receiving aerosol-generating material.

[0140] The heater or heating element may include any suitable heater. For example, the heater may include an induction heating system (e.g., including a coil and a sensor) or a resistance heating system (e.g., a resistance coil or a thin-film heater).

[0141] For example, such an induction heating system may include a coil disposed within device 1 and a sensor disposed within device 1 (e.g., disposed within or along an airflow path). Alternatively, the induction heating system may include a coil disposed within device 1 and a sensor disposed within consumable article 34.

[0142] refer to Figures 1 to 5 A non-combustible aerosol supply system or its non-combustible aerosol supply device 1 may include one or more flow deflectors 22 (e.g., airflow guides) configured to guide and / or converge a flow of hot air or heated air to a region 24 for receiving aerosol-generating material. The flow deflectors 22 may take any suitable form to guide the airflow. For example, each flow deflector 22 may be tubular or truncated conical in shape through which hot air or heated air can flow, and each flow deflector may include a nozzle configured to control the flow rate, velocity, direction, mass, shape, and / or pressure of the airflow exiting from it. One or more flow deflectors 22 may be configured to guide a flow of hot air or heated air to a portion of a consumable or consumable article 34 received within the region 24 for receiving aerosol-generating material. In some embodiments, the consumable article 34 may include one or more flow deflectors 22.

[0143] A non-combustible aerosol supply system or its non-combustible aerosol supply device 1 may include a variable or fractional flow guiding system. This variable or fractional flow guiding system may include one or more flow deflectors 22 and one or more movable baffle systems 26. The baffle system 26 may act as a gate, configured to selectively direct a flow of hot air or heated air to different portions of the region 24 for receiving aerosol-generating material, or selectively direct it to different portions of the consumable or consumable article 34 received within the region 24 for receiving aerosol-generating material. In some embodiments, device 1 may include the baffle system 26, and the consumable article 34 may include one or more flow deflectors 22.

[0144] refer to Figure 3 The baffle system 26 may include rotating baffles arranged to selectively block or obstruct one or more of the plurality of deflectors 22. The airflow path may be directed to one of the deflectors 22 or a group of deflectors (such as...). Figure 3 (As indicated by the arrow in the diagram). Alternatively, the baffle system 26 may include a rotary baffle arranged to selectively block or obstruct one or more portions of a single flow deflector 22. Any suitable mechanism can be used to rotate the baffle, such as a stepper motor.

[0145] refer to Figure 4 The baffle system 26 may include blade-type baffles arranged to selectively block or obstruct one or more of the plurality of deflectors 22. The airflow path may be directed to one of the deflectors 22 or a group of deflectors (such as...). Figure 4 (As indicated by the arrow in the diagram). Alternatively, the baffle system 26 may include blade-type baffles arranged to selectively block or obstruct one or more portions of a single flow deflector 22.

[0146] refer to Figure 5 One or more flow deflectors 22 may include one or more variable flow deflectors 22. The one or more variable flow deflectors 22 may be configured to change the direction of airflow. For example, the variable flow deflectors may be configured to rotate or tilt to direct airflow to different portions (e.g., portions distributed along the width or circumference) or sectors (such as...) of the region 24 for receiving aerosol-generating material. Figure 5 (Indicated by the arrow in the image). Figure 3 Similar to the baffle system 26, one or more variable diverters 22 can be operated using any suitable mechanism.

[0147] In any aspect and embodiment described herein, consumables for use with a non-combustible aerosol supply system or device 1 may include aerosol generating material 30. Consumables including aerosol generating material 30 may be aerosol generating membranes or may include aerosol generating membranes.

[0148] Region 24 for receiving aerosol-generating material can be configured (e.g., shaped, sized, and determined) to receive aerosol-generating membrane 30. Region 24 for receiving aerosol-generating material can be configured (e.g., shaped, sized, and determined) to receive consumable article 34. Region 24 for receiving aerosol-generating material may include a longitudinal axis along which an airflow path extends.

[0149] Region 24 for receiving aerosol-generating materials may include a channel (e.g., an elongated channel) defined by support structure 28. Support structure 28 may include or be formed from an inner cavity located in device 1.

[0150] The channel can be substantially linear; for example, the channel can extend along the longitudinal axis of the region 24 used to receive the aerosol-generating material. An airflow path can pass through this longitudinal axis. In some embodiments, the channel can be generally cylindrical, and / or the channel can have a circular or elliptical cross-section (e.g., as measured in a plane perpendicular to the longitudinal axis). In some embodiments, the channel can have a polygonal cross-section (e.g., triangular, square, or rectangular).

[0151] The channel can have a width or diameter less than 12 mm. The channel can have a width or diameter less than 10 mm. The channel can have a width or diameter between 4 mm and 10 mm. The channel can have a width or diameter between 8 mm and 10 mm. The channel can have a width or diameter between 6 mm and 8 mm. The channel can have a width or diameter between 4 mm and 6 mm.

[0152] The channel defines an aerosol generation section (e.g., a section including aerosol generating material 30, such as the portion of a consumable article 34 containing aerosol generating material 30). The aerosol generating material 30 can be arranged within the aerosol generation section to provide a controlled pressure drop over the aerosol generation section (e.g., from an inlet or upstream end to an outlet or downstream end of the aerosol generation section). The pressure drop over the aerosol generation section can be controlled based on the packing density of the aerosol generating material 30. For example, providing multiple aerosol generating material 30 films (e.g., with a higher packing density) in the channel can increase the pressure drop. The aerosol generation section can have a pressure drop between 0 mm Wg and 80 mm Wg (0 Pa – 785 Pa). The aerosol generation section can have a pressure drop less than 60 mm Wg (588 Pa). The aerosol generation section can have a pressure drop between 20 mm Wg and 60 mm Wg (196 Pa – 588 Pa). The aerosol generation zone can have a pressure drop of less than 20 mm Wg (196 Pa).

[0153] The pressure drop from the area 24 used for receiving consumables to the outlet 16 can be controlled (e.g., the pressure drop across the entire consumable article 34 from article inlet 44 to article outlet 46, as discussed further below). For example, it may be desirable to include a low-pressure-drop aerosol-generating section (e.g., a single-layer aerosol-generating material or a loosely packed spiral aerosol-generating material) while maintaining a relatively high pressure drop across the entire consumable article 34. This can improve the user's experience or taste. Other sections or portions of the consumable article 34 through which air flows (e.g., filters or end plugs, if present) can be made with relatively high pressure drops to compensate for the low pressure drop of the aerosol-generating sections and provide the desired overall pressure drop. The overall pressure drop from the area 24 used for receiving consumables to the outlet 16 (e.g., from article inlet 44 to article outlet 46) can be between 30 mm Wg and 95 mm Wg (294 Pa – 932 Pa). The overall pressure drop from the area 24 used to receive consumables to the outlet 16 (e.g., from the product inlet 44 to the product outlet 46) can be between 40 mm Wg and 70 mm Wg (392 Pa – 686 Pa).

[0154] The channel or aerosol generation section can have a length of less than 100 mm (e.g., axial length along the airflow direction). The channel or aerosol generation section can have a length of less than 80 mm. The channel or aerosol generation section can have a length between 20 mm and 80 mm. The channel or aerosol generation section can have a length between 20 mm and 60 mm. The channel or aerosol generation section can have a length between 30 mm and 40 mm.

[0155] refer to Figure 6A The aerosol generating material 30 can be arranged to intersect the region 24 for receiving the aerosol generating material along the airflow path. Here, the aerosol generating material 30 intersects the channel along a plane extending parallel to the longitudinal axis. The aerosol generating material 30 can be suspended across the channel by a support structure 28. The aerosol generating material 30 can have a surface area extending parallel to the longitudinal axis.

[0156] A first airflow path can be positioned on a first side of the aerosol generating material 30, and a second airflow path can be positioned on a second side of the aerosol generating material 30 (e.g., the aerosol generating material 30 can divide at least a portion of the airflow path from inlet 14 to outlet 16 into two parts). Suspending the aerosol generating material 30 within or across a channel increases the exposed surface area of ​​the aerosol generating material 30 (e.g., the surface area exposed to or brought into contact with a hot airflow or heated airflow). Suspending the aerosol generating material 30 within or across a channel provides a taut surface for the aerosol generating material 30 (the aerosol generating material 30 can be taut within or across a channel), which will achieve consistent fluid dynamics through the channel and / or a consistent user experience.

[0157] refer to Figure 6B The housing 10 may be configured with a cover 10A to allow access to the area 24 for receiving aerosol-generating material. The cover 10A may be positioned at the area 24 for receiving aerosol-generating material, for example, at a channel, and optionally provide access to the entire length of the channel. This is in Figure 6B As shown, a cover 10A divides the channel into two parts along a plane extending parallel to its longitudinal axis. The cover 10A can be removed to replace the aerosol generating material 30 (e.g., after a portion of the aerosol generating material 30 has been depleted). The channel can be opened such that the aerosol generating material 30 can be placed within the channel or arranged across the channel (e.g., a strip of aerosol generating material 30 can be placed in the channel).

[0158] refer to Figure 7A The aerosol generating material 30 may be unsupported (e.g., the aerosol generating material 30 may be substrate-free). For example, the aerosol generating material 30 may be self-supporting and can be replaced within the system or device 1 by, for example, opening the cover 10A. In some embodiments, the aerosol generating material 30 may be supported on a substrate (not shown). The substrate may include a porous substrate (e.g., cardboard, paper, tissue paper, mesh structure, etc.) or a non-porous substrate (e.g., plastic film or metal foil). Reference Figure 7BThe aerosol generating material 30 can be supported on the frame 32. The frame 32 can comprise cardboard, paper, a mesh structure, plastic, or metal. The frame 32 can be configured to provide rigid support to the aerosol generating material 30. The frame 32 can suspend the aerosol generating material 30, for example, by keeping it taut (as discussed above).

[0159] The aerosol generating material 30 may include multiple aerosol generating membranes 30 or multiple layers of aerosol generating material 30. Each aerosol generating membrane 30 or each layer of aerosol generating material 30 may be spaced apart from an adjacent aerosol generating membrane 30 or layer of aerosol generating material 30.

[0160] In embodiments including one or more flow deflectors 22, each layer of aerosol generating material 30 or membrane, or several layers of aerosol generating material 30 or membrane, can be aligned with a corresponding flow deflector 22. Spacers 36, 38 (see discussion below) can be provided between each layer of aerosol generating material or membrane 30 or between several layers of aerosol generating material or membrane 30. Figure 9 and Figure 11 The separator 36 may be porous / permeable (e.g., breathable). The separator 36 may support and align each layer of aerosol-generating material or membrane 30. The separator 36 may include a mesh structure. Alternatively, the separator 38 may be impermeable (e.g., a substantially airtight barrier) to form multiple individual air channels in the region 24 and / or support structure 28 for receiving the aerosol-generating material.

[0161] refer to Figures 8A to 14D Consumables, including aerosol-generating materials and configured for use with a non-combustible aerosol supply device, may include consumable articles 34 for use with a non-combustible aerosol supply system or device 1. Consumable article 34 is considered inventive in itself, and each consumable article may be claimed independently.

[0162] Each consumable article 34 includes an inlet (e.g., article inlet 44) and an outlet (e.g., article outlet 46). The outlet of the consumable article 34 may include or otherwise form the outlet 16 of a non-combustible aerosol supply system. A support structure 28 may be formed as part of the consumable article 34. For example, the consumable article 34 may define a channel and / or an aerosol generation section capable of removably receiving aerosol-generating material in a region 24 for receiving aerosol-generating material, as described above. The support structure 28 may be a generally tubular support structure, but other shapes may also be used.

[0163] Consumable article 34 may include a filter plug. Consumable article 34 may include a tubular region (e.g., a first tubular region, a hollow or internal tubular region, or a heat exchange tube or sleeve). The tubular region may be disposed between the channel (e.g., having aerosol generating material 30) and the filter plug. Consumable article 34 may include a second tubular region or a nozzle tip tube.

[0164] Consumable article 34 may have the same width or diameter as the channel (e.g., the channel may be defined by the wall or packaging paper of consumable article 34). Consumable article 34 may have a width or diameter less than 12 mm. Consumable article 34 may have a width or diameter less than 10 mm. Consumable article 34 may have a width or diameter between 4 mm and 10 mm. Consumable article 34 may have a width or diameter between 8 mm and 10 mm. Consumable article 34 may have a width or diameter between 6 mm and 8 mm. Consumable article 34 may have a width or diameter between 4 mm and 6 mm.

[0165] The overall length of consumable article 34 (e.g., including the length of each of the channel / aerosol generation section, filter plug (if present), tubular region (if present), and nozzle end tube (if present)) may be less than 100 mm. The overall length of consumable article 34 may be less than 80 mm. The overall length of consumable article 34 may be between 50 mm and 80 mm. The overall length of consumable article 34 may be between 70 mm and 80 mm.

[0166] The perimeter of consumable item 34 may be less than 30 mm. The perimeter of consumable item 34 may be between 23 mm and 25 mm. The perimeter of consumable item 34 may be 25 mm. The perimeter of consumable item 34 may be between 22 mm and 23 mm. The perimeter of consumable item 34 may be between 19 mm and 22 mm. The perimeter of consumable item 34 may be between 16 mm and 19 mm. The perimeter of consumable item 34 may be less than 16 mm.

[0167] refer to Figure 8A and Figure 8BThe aerosol generating material 30 may include multiple aerosol generating membranes 30 or multiple layers of aerosol generating material 30 (which may generally be referred to as aerosol generating membrane 30). Each aerosol generating membrane 30 or each layer of aerosol generating material 30 may be spaced apart from an adjacent aerosol generating membrane 30 or a single layer of aerosol generating material 30 within a support structure (e.g., each layer of aerosol generating material or aerosol generating membrane 30 may have surface areas extending parallel to the longitudinal axis at different diameter locations across the width of the support structure or channel). One or more membranes 30 may be taut across the support structure. The spacing between the layers of aerosol generating membrane 30 may be between 10 micrometers and 10 mm. This spacing may be 0.5 mm, 1.0 mm, or 1.5 mm. Each aerosol generating membrane 30 or each group of aerosol generating membranes 30 may be configured to be aligned with a corresponding flow guide 22. For example, the consumable article 34 and the area 24 for receiving the aerosol generating material may include corresponding alignment features to allow alignment with one or more flow guides (not shown).

[0168] refer to Figures 9 to 11 Separators 36 and 38 can be provided between each aerosol-generating membrane 30 or each group of aerosol-generating membranes 30. Each separator 36 and 38 can separate a first volume (containing the first aerosol-generating membrane 30 or the first group of aerosol-generating membranes 30) within the article 34 and / or support structure 28 from an adjacent second volume (containing the second aerosol-generating membrane 30 or the second group of aerosol-generating membranes 30). This separation can be spatial, for example, airflow can exist between the volumes, such as... Figure 9 As in the implementation method. Alternatively, this separation can be fluid-separated, making it impossible for direct airflow to exist between adjacent volumes, for example, as... Figures 10 to 11 As shown in the diagram (but it should be noted that the fluid passing through the volume section usually originates from the same source).

[0169] Each aerosol generating membrane 30 may have a surface area extending parallel to the longitudinal axis, and each separator may have a surface area extending parallel to the longitudinal axis. The separator 36 may be porous or permeable (e.g., a permeable support 36). The separator 36 may support and align each aerosol generating membrane 30.

[0170] refer to Figure 9The separator 36 may include a mesh structure (e.g., a porous mesh material). This mesh structure can support the aerosol generating material 30 and allow air (e.g., a hot airflow or heated airflow generated by the aerosol generator 20) to pass through. Multiple mesh separators 36 may be provided. Each layer of aerosol generating material or film 30 may be stacked on a corresponding mesh separator or layer 36 (e.g., alternating stacks of multiple layers of aerosol generating material or film 30 and mesh separators or layers 36 may be provided). The mesh structure (or multiple mesh separators or layers) can allow airflow to pass axially through the mesh structure (e.g., across the plane in which the mesh structure is arranged). The hot airflow or heated airflow can heat the mesh structure, and the mesh structure can transfer heat to the aerosol generating material 30. In the case where the consumable article 34 includes the aerosol generator 20, the mesh structure may contact the aerosol generator 20 or form part of the aerosol generator. For example, the mesh structure can be a heated mesh structure (e.g., including a heater) and can be induction heated. The mesh structure can be a sensor arranged to be heated by a coil arranged in device 1.

[0171] refer to Figures 10 to 11 The separator 38 may be impermeable to form multiple channels (e.g., a substantially airtight barrier) within the support structure 28 of the consumable article 34. Figure 10 As shown, the separator 38 can divide the consumable article 34 or its support structure into discrete channels. Each channel may include one or more layers of aerosol generating material 30 or one or more aerosol generating material membranes. Each channel may include a group of aerosol generating membranes from a plurality of aerosol generating membranes 30.

[0172] Each channel can be aligned with a corresponding flow deflector 22, or with a variable flow deflector 22 (e.g., such as...). Figure 5 The corresponding indexing positions are aligned such that each channel provides a discrete aerosolization session (e.g., a session for aspirating 5-10 puffs of aerosol). The system or its apparatus can be configured to switch channels mid-session (e.g., using the variable flow deflector 22 described above). For example, the system can be configured to first provide 3-5 puffs from the first channel (e.g., determined by a puff sensor), and then switch to the second channel for another 3-5 puffs. The system, apparatus 1, or its controller can be configured to automatically switch channels (e.g., automatically adjust the variable flow deflector 22, or automatically adjust the baffle system 26). The system or apparatus 1 can also be configured to allow manual switching between channels (e.g., through user intervention).

[0173] refer to Figure 11The consumable article 34 may include multiple separators 38 and multiple layers or sheets of aerosol generating material or aerosol generating membrane 30 (which may also be referred to as aerosol generating membrane 30), with each separator 38 arranged adjacent to a corresponding aerosol generating membrane 30. The multiple separators 38 may form multiple channels, each channel having aerosol generating material 30. The system, apparatus 1, or its controller may be configured to automatically switch channels after each suction (e.g., using the variable flow guide 22 described above). This can improve the consistency of suction per intake. For example, each suction may use fresh or previously unused (or less recently used) aerosol generating material 30. The variable or fractional flow guide system may be configured to direct a flow of hot air or heated air to the adjacent corresponding channel after each suction.

[0174] refer to Figures 12A to 12B The consumable article 34 may include aerosol-generating material rolled into a spiral shape (e.g., one or more aerosol-generating films 30), which may be referred to as spiral aerosol-generating material 30 (e.g., Archimedes spiral aerosol-generating material 30), or generally as a spiral structure. The rolled or spiral aerosol-generating material 30 may radiate from a central spiral axis (e.g., when viewed from the end face, the roll may be a two-dimensional spiral that projects along the spiral axis to form a three-dimensional spiral roll). The spiral axis may be parallel to the longitudinal axis of the region 24 for receiving the aerosol-generating material, the support structure 28, and / or the consumable article 34. The surface area of ​​the spiral structure may extend parallel to the longitudinal axis.

[0175] One or more helical aerosol generating materials 30 can be suspended and optionally taut across the channel. For example, see reference. Figure 12A One or more helical aerosol generating materials 30 may be supported by a frame 40 intersecting with the support structure 28. Alternatively, one or more helical aerosol generating materials 30 may be supported by a rod or other support (e.g., an elongated or axial support, or a rod) from which the helical structure radiates (not shown). The rod or other support may be held in place by any suitable means (e.g., held in place by a frame or end cap).

[0176] One or more helical aerosol generating materials 30 can be axially suspended, for example, as shown in the figure. Figure 12AAs shown. Here, a first frame 40 or mesh structure is provided near the article inlet 44, and a second frame 40 or mesh structure is provided near the article outlet 46. One or more spiral aerosol generating materials 30 can be suspended (e.g., kept taut) between the first frame or mesh structure and the second frame 40 or mesh structure. The aerosol generating material 30 can be disposed on the spiral mesh structure (not shown). For example, the aerosol generating material 30 can be coated, impregnated, or suspended on the mesh structure (e.g., a metal mesh), which can be arranged or formed in a spiral shape (e.g., the mesh structure with the aerosol generating material 30 can be rolled into a spiral shape). The mesh structure can contain sensing material (e.g., the mesh structure can act as a sensor for inductive heating).

[0177] Alternatively, one or more helical aerosol generating materials 30 may be disposed within and axially held within the consumable article 34 or the support structure 28. For example... Figure 13A As shown, one or more helical aerosol generating materials 30 can be encapsulated within a consumable article. For example, one or more helical aerosol generating materials 30 can be inserted into a consumable article 34 or a support structure 28, and held in place, for example, by caps 50 located at each of the article inlet 44 and article outlet 46. Each cap 50 may include a mesh structure or any other suitable permeable structure (e.g., a filter medium), or a combination of materials and structures that allow airflow through the consumable article 34 or support structure 28. For example, a mesh structure may be provided at the article inlet 44 end, and a filter tip may be provided at the article outlet 46 end. One or more helical aerosol generating materials 30 may be movable within the channel (e.g., loosely or otherwise freely movable within the channel, such as circumferentially and / or radially). Reference Figure 13B The spiral aerosol generating material 30 can be held within the channel via an interference fit (e.g., the spiral structure can be more tightly compressed / rolled up to be inserted into the channel and can be unrolled into space). This interference fit can be provided as a supplement to or alternative to the encapsulation or suspension described above. Reference Figure 13C The spiral aerosol generating material 30 can be adhered to the channel at the outer end of the spiral structure (e.g., as a supplement or alternative to the encapsulation, suspension, or interference fit described above). For example, dotted or strip-shaped adhesive 52 can be applied to the surface of the support structure 28 or to the spiral aerosol generating material 30 to adhere the spiral structure to the consumable article 34.

[0178] refer to Figure 12BMultiple helical aerosol generating materials 30 can be disposed in corresponding multiple channels defined within the support structure 28. Each helical aerosol generating material 30 can have a surface area extending parallel to a longitudinal axis. Each helical structure can be held in each corresponding channel in one or more of the various methods described above (e.g., suspension, encapsulation, deployment, and / or adhesion). Each channel can be coupled with a variable or graduated flow guiding system (e.g., as described above and in...). Figure 3 Aligned with the corresponding guide 22 (shown in the diagram), or with the variable guide 22 (e.g., as described above and in...). Figure 5 Align the corresponding graduation positions (as shown in the diagram).

[0179] Several tests have been conducted using an aerosol generator 20 comprising a heating device (e.g., a convection heating system) configured to provide a flow of hot air, and aerosol-generating material 30 suspended across a channel spanning a support structure 28. The tests used a cylindrical channel with an inner diameter of 8 mm and an axial length of 40 mm. Five layers of aerosol-generating material 30 were suspended across the center of the channel, which had a length of 40 mm and a diameter of 8 mm (according to...). Figure 8A The arrangement shown makes 1417 mm 2 The area of ​​aerosol generating material 30 exposed in the channel (resulting in a total exposed surface area of ​​2834 mm² on both sides of aerosol generating material 30) 2 The channel is exposed to simulated suction conditions using controlled pulses of hot air or heated air. The temperature of the hot air or heated air is controlled to a set temperature and is applied at approximately 1 liter (1 dm³) per minute during the duration of each simulated suction. 3 The supply was at a flow rate of ( / min). Each simulated suction lasted 3 seconds. The amount of aerosol produced per simulated suction was determined by measuring the mass change (mass reduction) of the aerosol-generating material 30 after each suction. Tables 1 and 2 and... Figure 16 The results of these tests are shown.

[0180] Table 1: Mass of aerosols generated by simulated suction at constant temperature

[0181] Refer to Table 1 and Figure 16 Tests showed that the aerosol mass produced by each puff may be inconsistent. For example, when using a constant air temperature of 270°C, the first puff may produce a relatively larger aerosol volume and / or mass than subsequent puffs. We believe that such variations between puffs, or the resulting inconsistencies in aerosol volume and / or mass, may adversely affect the user experience. (Reference) Figures 3 to 5 and Figures 9 to 11By incorporating one or more separators 36, 38 between adjacent membranes and combining them with a variable or indexing flow system, the consistency of aerosol volume and / or mass generated per-aperture can be improved. For example, each aspiration can be indexed to a new (e.g., fresh or previously unused) aerosol-generating membrane 30, or to a new (e.g., fresh or previously unused) portion of the aerosol-generating material 30. In this way, each aspiration can produce the same or similar aerosol volume and / or mass as the "first aspiration." Of course, various other advantages of the described arrangement are detailed elsewhere in this document.

[0182] Figures 14A to 14D Examples are shown that demonstrate improved consistency in the volume and / or quality of aerosols generated per-pump aspiration. In general, these advantages can be achieved when using a multilayer aerosol-generating material 30 that includes features that stagger the amounts of material exposed to hot air or heated air during use. These layers can be corresponding aerosol-generating film layers.

[0183] exist Figures 14A to 14D In the example shown, multiple layers of aerosol generating material 30 are arranged in the support structure 28. These layers can be corresponding aerosol generating film layers.

[0184] Each layer 30 has a first end located near an inlet (e.g., near the article inlet 44, aerosol generator 20, and / or flow deflector 22) and a second end located near an outlet 16. The first end of the first layer 30 is axially offset (relative to the longitudinal axis) relative to the first end of the adjacent (i.e., immediately adjacent) second layer 30. In the example shown, the end of the layer 30 near the center of the channel is axially closer to the aerosol generator 20 than the end of the adjacent (i.e., immediately adjacent) layer 30, which is axially further away from the aerosol generator 20. Multiple layers can have multiple different axial lengths. Multiple layers can each have the same axial length (some layers may be further offset toward the aerosol generator), or their lengths can be different.

[0185] By offsetting or staggering the axial positions of the corresponding first ends of each layer (particularly in the airflow direction), the volume and / or mass of aerosol drawn up per puff can be adjusted. In this way, layer 30 can be configured to provide a consistent puffing experience. Figures 14B to 14D As shown, each suction inlet consumes a portion of multiple layers in the propulsion front formed by the laminar flow of hot air or heated air (the consumed portion of layer 30 is shown as from...). Figures 14B to 14D (Increase). By offsetting the layers 30 in the direction of the hot airflow or the heated airflow, the portion of the aerosol generating material 30 consumed in the first suction can be reduced, thereby reducing the volume and / or mass of the aerosol in the first suction.

[0186] In addition to the location of the aerosol generating material 30 within the article 34 or the support structure 28, or as an alternative, the aerosol generating material may include inherent features that improve the consistency of the volume and / or mass of aerosols generated during continuous aspiration. For example, a plurality of perforations 42 may be provided in each of one or more aerosol generating layers 30, wherein the number and / or size of the perforations 42 are configured to adjust the volume and / or mass of aerosols generated during continuous aspiration.

[0187] exist Figure 15 In this example, the aerosol generating material 30 may include a relatively large perforation 42 near the aerosol generator 20 and / or the article inlet 44, and a relatively small perforation 42 near the outlets 16, 46. The larger perforation 42 near the aerosol generator 20 and / or the article inlet 44 can reduce the volume of aerosol generating material consumed during the first suction, thereby improving the consistency of aerosol volume and / or quality generated by each suction.

[0188] Several tests have also been conducted using an aerosol generator 20 comprising a heating device configured to provide a flow of hot air, and aerosol-generating material 30 suspended across a channel spanning a support structure 28, wherein each puff was performed at a variable temperature. The experimental setup was the same as that shown previously, except that the temperature for each simulated puff was set to a different value. Table 2 shows the results of one such test, where the temperature gradually increased after each puff.

[0189] Table 2: Mass of aerosols generated by simulated pumping at gradually increasing temperatures

[0190] Refer to Table 2 and Figure 16 Tests show that by using gradually increasing temperatures between aspirations, the consistency of aerosol volume and / or quality generated by aspiration can be improved.

[0191] Unless otherwise expressly stated, all weight percentages (expressed in wt%) described herein are calculated on a dry weight basis. All weight ratios are also calculated on a dry weight basis. Weights referenced on a dry weight basis refer to the total weight of the extract, slurry, or material excluding water, and may include components that are liquid at room temperature and pressure, such as glycerol. Conversely, weight percentages referenced on a wet weight basis refer to all components, including water.

[0192] For the avoidance of doubt, where the term "comprising" is used in this specification to define the invention or its features, embodiments in which the terms "consistently comprising" or "comprises" may be used instead of "comprising" to define the invention or its features are also disclosed. Material referring to "comprising" certain features means that those features are included, contained in, or retained within the material.

[0193] 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 those specifically described herein, various embodiments of the invention may suitably include, consist of, or substantially consist of suitable combinations of the disclosed elements, components, features, portions, steps, methods, etc., or be composed of suitable combinations of the disclosed elements, components, features, portions, steps, methods, etc. Furthermore, this disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. An article (34) for providing an aerosol, comprising: Entrance (44); Exports (46); Support structure (28) defines a channel extending along the longitudinal axis; as well as Aerosol generating material (30), the aerosol generating material (30) being configured to provide an aerosol containing at least one volatile component of the aerosol generating material when heated; At least a portion of the aerosol generating material (30) is suspended within the channel, such that both sides of the at least a portion of the aerosol generating material are arranged to be exposed to the airflow passing through the channel.

2. A system for providing aerosols from an aerosol-generating material, the system comprising: Entrance (14); The outlet (16) allows the user to perform a suction action; Support structure (28) defines a channel extending along the longitudinal axis; Aerosol generating material (30) is configured to provide an aerosol containing at least one volatile component of the aerosol generating material when heated, wherein at least a portion of the aerosol generating material (30) is suspended in the channel such that both sides of the at least a portion of the aerosol generating material are arranged to be exposed to an airflow through the channel; Heating device (20) for heating the aerosol generating material, wherein the heating device is configured to heat the airflow flowing into the system from the inlet (14) when a user performs a suction action at the outlet (16) during use; and A flow deflector (22) is configured to guide the heated airflow into the channel.

3. The system according to claim 2, wherein, The flow deflector (22) is configured to selectively guide the heated airflow into the channel in multiple different directions.

4. The system of claim 2, further comprising a movable baffle (26) configured to selectively block the heated airflow from entering the channel, or to direct the heated airflow to one or more of a plurality of different locations along the width of the channel.

5. The system of claim 2, 3 or 4, comprising a sensor configured to detect when a user performs a suction action at the outlet.

6. The system according to claim 5, wherein, The system is configured to increase the temperature of the heating device (20) after the sensor detects that the user has performed a suction action at the outlet.

7. The system according to claim 5 or 6, wherein, The system is configured to raise the temperature of the heating device (20) from a first temperature to a second temperature after the sensor detects that the user has performed a suction action on the outlet (16), and wherein, after the first temperature increase, the system is configured to further raise the temperature of the heating device (20) from the second temperature to a third temperature after the sensor detects that the user has further performed a suction action on the outlet (16).

8. The article of manufacture according to claim 1, or the system according to any one of claims 2 to 7, wherein, The two sides include the opposing surfaces of the aerosol generating material.

9. The article of claim 1 or 8, or the system of any one of claims 2 to 8, wherein, The aerosol generating material (30) includes perforations (42).

10. The article of manufacture according to any one of claims 1, 8, or 9, or the system according to any one of claims 2 to 9, wherein, The aerosol generating material (30) includes a plurality of aerosol generating membranes (30), each of the aerosol generating membranes (30) being spaced apart from the adjacent aerosol generating membranes (30).

11. The article of manufacture according to claim 10, or the system according to claim 10, wherein, One of the plurality of aerosol generating membranes (30) is separated from the adjacent aerosol generating membrane (30) by a separator.

12. The article of manufacture according to claim 11, or the system according to claim 11, wherein, The separator is breathable.

13. The article of manufacture according to claim 11, or the system according to claim 11, wherein, The separator is essentially airtight.

14. The article of manufacture according to claim 10, or the system according to claim 10, wherein, The plurality of aerosol generating membranes (30) are axially offset such that some of the plurality of aerosol generating membranes (30) are positioned closer to the inlet (14) than others of the plurality of aerosol generating membranes (30).

15. The article of manufacture according to any one of claims 1, 8, or 9, or the system according to any one of claims 2 to 9, wherein, The aerosol generating material (30) is a spiral aerosol generating material (30).

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