Aerosol Delivery Systems

Abstract

The present invention relates to an article for use as part of a non-flammable aerosol delivery system, comprising an aerosol generating component and an aerosol-generating material transfer component configured to transfer an aerosol-generating material to the aerosol generating component, wherein the aerosol generating component and the aerosol-generating material transfer component are magnetically connected to one another.

Description

Field

[0001] The present invention relates to a delivery system, and in particular to a non-flammable aerosol delivery system and components of said aerosol delivery system. Additionally, the present invention relates to a method of generating and delivering aerosols using the non-flammable aerosol delivery system and components disclosed herein.

[0002] Non-flammable aerosol delivery systems are known in the art that generate an aerosol that is inhaled by a user. Such systems typically include an aerosol generator capable of converting an aerosolizable material into an aerosol. In some examples, the aerosol generated is a condensation aerosol, where the aerosolizable material is first vaporized and then condensed into an aerosol. In other examples, the aerosol generated is an aerosol resulting from atomization of the aerosolizable material. Such atomization may be effected mechanically, for example, by vibrating the aerosolizable material to form small particles of the material that are entrained in an airflow. Alternatively, such atomization may be effected in other ways, such as electrostatically or by the use of pressure.

[0003] Because such aerosol delivery systems are intended to generate an aerosol that is inhaled by a user, the characteristics of the aerosol generated should be considered. These characteristics may include the size of the aerosol particles, the total amount of aerosol generated, etc.

[0004] Controlling these various characteristics is particularly important when the aerosol delivery system is used to simulate a smoking experience, for example as an e-cigarette or similar product, because the user may expect a particular sensory experience as a result of using the system.

[0005] It would be desirable to provide an aerosol delivery system with improved control over these properties. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] International Publication No. 2010 / 045670 [Patent Document 2] International Publication No. 2010 / 045671 [Patent Document 3] Overview of International Publication No. 2018 / 211252

[0007] According to one aspect of the present disclosure, there is provided an article for use as part of a non-flammable aerosol delivery system, comprising: a housing having at least one air inlet; a substantially planar aerosol generating component contained in a housing; Equipped with An article is provided in which at least one air inlet is configured to direct air in an inlet airflow direction towards the aerosol generating component, and a plane of the substantially planar aerosol generating component is angled obliquely relative to the inlet airflow direction.

[0008] In some instances, the plane of the substantially planar aerosol generation component is angled at about 140° to about 160° with respect to the inlet airflow direction.

[0009] In some instances, the plane of the substantially planar aerosol generation component is angled at about 130° to about 150° with respect to the inlet airflow direction.

[0010] In some examples, the plane of the aerosol generation component is angled obliquely to the inlet airflow direction in one or more directions.

[0011] In some instances, the plane of the aerosol generation component is angled obliquely to the inlet airflow direction in only one direction.

[0012] In some instances, the housing comprises an aerosol formation chamber.

[0013] In some examples, the aerosol generation component is disposed at least partially within the aerosol formation chamber.

[0014] In some examples, the housing defines a single airflow channel.

[0015] In some examples, a single air flow channel extends between at least one air inlet and at least one air outlet.

[0016] In some examples, the aerosol generation component includes one or more elongated openings.

[0017] In some instances, the aerosol generating component is formed from an electrically conductive material.

[0018] In some instances, the aerosol-generating material is formed of a porous material.

[0019] In some instances, the aerosol generating component is formed in a single layer.

[0020] In some instances, the aerosol generation component comprises one or more electrical connectors.

[0021] In some instances, the article comprises a reservoir for the aerosolizable material.

[0022] In some examples, the article includes an aerosol-generating material transfer component configured to transfer (eg, by capillary forces) the aerosolizable material from the reservoir to the aerosol-generating component.

[0023] According to one aspect of the present disclosure, there is provided a non-flammable aerosol delivery system comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0024] According to one aspect of the present disclosure, there is provided an article for use as part of a non-flammable aerosol delivery system, the article comprising: an aerosol generating component; and an aerosol-generating material transfer component configured to transfer an aerosol-generating material to the aerosol generating component, wherein the aerosol generating component and the aerosol-generating material transfer component are magnetically connected to one another.

[0025] In some examples, one of the aerosol-generating component and the aerosol-generating material transfer component includes a magnetic material, and the other of the aerosol-generating component and the aerosol-generating material transfer component includes a corresponding magnetic material.

[0026] In some examples, one or both of the magnetic material and the corresponding magnetic material are permanent magnets.

[0027] In some examples, one or both of the magnetic material and the corresponding magnetic material are temporary magnets or electromagnets.

[0028] In some instances, the aerosol generating component is substantially planar.

[0029] In some examples, the aerosol generation component is curved.

[0030] In some examples, the aerosol generation component is curved about the axis of the aerosol generation component.

[0031] In some instances, the aerosol-generating material transfer component is curved about the axis of the aerosol-generating component.

[0032] In some instances, the article comprises an aerosol-forming chamber.

[0033] In some examples, the aerosol generation component is at least partially disposed in the aerosol formation chamber.

[0034] In some examples, the aerosol generation component includes one or more elongated openings.

[0035] In some examples, the aerosol generation component comprises a plurality of elongated heating sections, which may be arranged side-by-side.

[0036] In some examples, an elongated opening is provided between adjacent elongated heating portions.

[0037] In some instances, the aerosol generating component is formed from an electrically conductive material.

[0038] In some instances, the aerosol-generating material is formed of a porous material.

[0039] In some instances, the aerosol generating component is formed in a single layer.

[0040] In some instances, the aerosol-generating component and the aerosol-generating material transfer component are non-permanently connected to one another.

[0041] In some examples, the aerosol-generating component and the aerosol-generating material transfer component are releasably connected to one another.

[0042] In some instances, the article comprises a reservoir for the aerosolizable material.

[0043] In some examples, the aerosol generating material transfer component is configured to transfer aerosolizable material from the reservoir to the aerosol generating component.

[0044] According to one aspect of the present disclosure, there is provided a non-flammable aerosol delivery system comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0045] According to one aspect of the present disclosure, an aerosol generation component is provided that comprises at least two substantially planar portions, at least two of the substantially planar heating portions being in different planes from one another.

[0046] In some instances, at least two of the substantially planar portions that lie in different planes define an oblique interior angle.

[0047] In some examples, the interior angle is between about 30° and about 60°.

[0048] In some instances, the interior angle is between about 40° and about 50°.

[0049] In some instances, at least two of the substantially planar portions that lie in different planes are connected to one another end-to-end.

[0050] In some instances, the aerosol generation component (eg, one or all of the at least two substantially planar portions) includes one or more elongated openings.

[0051] In some examples, the aerosol generation component (e.g., one or all of the at least two substantially planar portions) comprises a plurality of elongated heating portions, which may be arranged side-by-side.

[0052] In some examples, an elongated opening is provided between adjacent elongated heating portions.

[0053] In some examples, the aerosol generation component is configured such that the air flow moves perpendicular to a boundary between at least two substantially planar portions that reside in different planes.

[0054] In some instances, the aerosol generating component is formed from an electrically conductive material.

[0055] In some instances, the aerosol generating component is formed of a porous material.

[0056] In some instances, the aerosol generating component is formed of a single layer.

[0057] According to one aspect of the present disclosure, there is provided an article for use as part of a non-flammable aerosol delivery system, the article comprising an aerosol generating component according to the previous aspect and one or more of a reservoir for an aerosolizable material and an aerosol formation chamber.

[0058] In some examples, the aerosol generation component is disposed at least partially within the aerosol formation chamber.

[0059] In some instances, the article comprises at least one air inlet to the aerosol formation chamber.

[0060] In some examples, the aerosol generating component is configured to direct air entering the article via at least one air inlet to at least two of the substantially planar portions that reside in different planes.

[0061] In some examples, at least two of the substantially planar portions that lie in different planes are configured to direct air entering the article via the at least one air inlet in different directions.

[0062] In some instances, the oblique interior angle is distal from the at least one air inlet with respect to the aerosol generation component.

[0063] In some examples, the article is configured such that air flow (e.g., entering via at least one air inlet) moves perpendicular to a boundary between at least two substantially planar portions that reside in different planes.

[0064] According to one aspect of the present disclosure, there is provided a non-flammable aerosol delivery system comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0065] According to one aspect of the present disclosure, there is provided an article for use as part of a non-flammable aerosol delivery system, the article comprising a housing, an aerosol generating component, and an aerosol-generating material movement component, wherein the aerosol generating component and the aerosol-generating material movement component are contained within the housing, and the aerosol generating component is biased relative to the aerosol-generating material movement component.

[0066] In some instances, the aerosol generating component is securely attached to the housing or a component thereof.

[0067] In some examples, the aerosol generation component includes one or more electrical connectors that are securely attached to one or more corresponding electrical contacts in the housing.

[0068] In some instances, the aerosol-generating material transfer component is spatially constrained by the housing or a component thereof.

[0069] In some instances, the aerosol generating component is substantially planar.

[0070] In some examples, the aerosol generation component is curved.

[0071] In some examples, the aerosol generation component is curved about the axis of the aerosol generation component.

[0072] In some instances, the aerosol-generating material transfer component is curved about the axis of the aerosol-generating component.

[0073] In some examples, the axis of the aerosol generating component is one or more of a longitudinal axis of the aerosol generating component and an axis extending between electrical contacts of the aerosol generating component.

[0074] In some instances, the article comprises an aerosol-forming chamber.

[0075] In some instances, the aerosol generation component is at least partially disposed in the aerosol formation chamber.

[0076] In some examples, the aerosol generation component includes one or more elongated openings.

[0077] In some examples, the aerosol generation component comprises a plurality of elongated heating sections, which may be arranged side-by-side.

[0078] In some examples, an elongated opening is provided between adjacent elongated heating portions.

[0079] In some instances, the aerosol generating component is formed from an electrically conductive material.

[0080] In some instances, the aerosol-generating material is formed of a porous material.

[0081] In some instances, the aerosol generating component is formed in a single layer.

[0082] In some examples, the housing defines at least one airflow channel.

[0083] According to one aspect of the present disclosure, there is provided a non-flammable aerosol delivery system comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0084] The system can be configured such that the airflow channel(s), the aerosol generation chamber(s), and / or the aerosol generation component(s) are separable. For example, the article can be provided in a modular format such that the airflow channel(s), the aerosol generation chamber(s), and / or the aerosol generation component(s) are separable.

[0085] According to another aspect of the present disclosure, there is provided:

[0086] A1. An article for use as part of a non-flammable aerosol delivery system, comprising: an aerosol generating component; and an aerosol-generating material transfer component configured to transfer an aerosol-generating material to the aerosol generating component, wherein the aerosol generating component and the aerosol-generating material transfer component are magnetically connected to one another.

[0087] A2. The article of clause A1, wherein one of the aerosol-generating component and the aerosol-generating material transfer component comprises a magnetic material, and the other of the aerosol-generating component and the aerosol-generating material transfer component comprises a corresponding magnetic material.

[0088] A3. The article of clause A2, wherein one or both of the magnetic material and the corresponding magnetic material are permanent magnets.

[0089] A4. The article of clause A2 or A3, wherein one or both of the magnetic material and the corresponding magnetic material is a temporary magnet or an electromagnet.

[0090] A5. The article of any one of clauses A1-A4, wherein the aerosol-generating component is substantially planar.

[0091] A6. The article of any one of clauses A1-A5, wherein the aerosol generation component is curved.

[0092] A7. The article of clause A6, wherein the aerosol-generating component is curved about the axis of the aerosol-generating component.

[0093] A8. The article of clause A7, wherein the aerosol-generating material transfer component is curved about the axis of the aerosol-generating component.

[0094] A9. The article of any one of clauses A1-A8, comprising an aerosol-forming chamber.

[0095] A10. The article of any one of clauses A1-A9, wherein the aerosol-generating component is at least partially disposed in the aerosol-formation chamber.

[0096] A11. The article of any one of clauses A1-A10, wherein the aerosol-generating component includes one or more elongated openings.

[0097] A12. The article of any one of clauses A1-A11, wherein the aerosol-generating component is formed from an electrically conductive material.

[0098] A13. The article of any one of clauses A1-A12, wherein the aerosol-generating component is formed of a porous material.

[0099] A14. The article of any one of clauses A1-A13, wherein the aerosol-generating component is formed of a single layer.

[0100] A15. The article of any one of clauses A1-A14, wherein the aerosol-generating component and the aerosol-generating material transfer component are non-permanently connected to one another.

[0101] A16. The article of any one of clauses A1-A15, wherein the aerosol-generating component and the aerosol-generating material transfer component are releasably connected to one another.

[0102] A17. The article of any one of clauses A1-A16, comprising a reservoir for aerosolizable material, the aerosol generating material transfer component configured to transfer the aerosolizable material from the reservoir to the aerosol generating component.

[0103] A18. A non-flammable aerosol delivery system comprising an article according to any one of clauses A1-A17 and a device comprising one or more of a power source and a controller.

[0104] According to another aspect of the present disclosure, there is provided:

[0105] B1. An aerosol-generating component comprising at least two substantially planar portions, at least two of the substantially planar portions being in different planes from one another.

[0106] B2. The aerosol-generating component of clause B1, wherein at least two of the substantially planar portions that lie in different planes define an oblique interior angle.

[0107] B3. The aerosol-generating component of clause B2, wherein the interior angle can be from about 30° to about 60°.

[0108] B4. The aerosol-generating component of clause B3, wherein the interior angle can be from about 40° to about 50°.

[0109] B5. The aerosol-generating component of any one of clauses B1-B4, wherein at least two of the substantially planar portions that lie in different planes are connected to each other end-to-end.

[0110] B6. An aerosol generation component according to any one of clauses B1 to B5, comprising one or more elongated apertures.

[0111] B7. The aerosol generating component of clause B6, comprising a plurality of elongated heating sections.

[0112] B8. The aerosol generation component of clause B7, wherein an elongated opening is provided between adjacent elongated heating sections.

[0113] B9. The aerosol generating component of any one of clauses B1-B8, configured such that the air flow moves perpendicular to a boundary between at least two substantially planar portions that lie in different planes.

[0114] B10. The aerosol generating component of any one of clauses B1-B9, formed from a conductive material.

[0115] B11. The aerosol-generating component of any one of clauses B1-B10, which is formed of a porous material.

[0116] B12. An aerosol-generating component according to any one of clauses B1-B11, which is formed of a single layer.

[0117] B13. An article for use as part of a non-flammable aerosol delivery system, comprising an aerosol generating component according to any one of clauses B1-B12 and one or more of a reservoir for an aerosolizable material and an aerosol formation chamber.

[0118] B14. The article of clause B13, wherein the aerosol-generating component is disposed at least partially within the aerosol-formation chamber.

[0119] B15. The article of clause B13 or B14, comprising at least one air inlet to the aerosol formation chamber.

[0120] B16. The article of clause B15, wherein the aerosol-generating component is configured to direct air entering the article through at least one air inlet into at least two of the substantially planar portions that reside in different planes.

[0121] B17. The article of clause B15 or B16, wherein at least two of the substantially planar portions that lie in different planes are configured to direct air entering the article through the at least one air inlet in different directions.

[0122] B18. The article of any one of clauses B15-B17, wherein the aerosol-generating component is characterized according to clause B2, and the oblique internal angle is distal to the at least one air inlet for the aerosol-generating component.

[0123] B19. The article of any one of clauses B13-B18, configured for air flow to move perpendicular to a boundary between at least two substantially planar portions that lie in different planes.

[0124] B20. A non-flammable aerosol delivery system comprising an article according to any one of clauses B13-B19 and a device comprising one or more of a power source and a controller.

[0125] According to another aspect of the present disclosure, there is provided:

[0126] C1. An article for use as part of a non-flammable aerosol delivery system, comprising: a housing; an aerosol generating component; and an aerosol-generating material transfer component, wherein the aerosol generating component and the aerosol-generating material transfer component are contained within the housing, and the aerosol generating component is biased relative to the aerosol-generating material transfer component.

[0127] C2. The article of clause C1, wherein the aerosol-generating component is securely attached to the housing or a component thereof.

[0128] C3. The article of clause C1 or C2, wherein the aerosol generating component comprises one or more electrical connectors securely attached to one or more corresponding electrical contacts of the housing.

[0129] C4. The article of any one of clauses C1-C3, wherein the aerosol-generating material transfer component is spatially constrained by the housing or a component thereof.

[0130] C5. The article of any one of clauses C1-C3, wherein the aerosol-generating material transfer component is not securely attached to the housing or a component thereof.

[0131] C6. The article of any one of clauses C1-C5, wherein the aerosol-generating component is substantially planar.

[0132] C7. The article of any one of clauses C1-C6, wherein the aerosol-generating component is curved.

[0133] C8. The article of clause C7, wherein the aerosol-generating component is curved about the axis of the aerosol-generating component.

[0134] C9. The article of clause C7 or C8, wherein the aerosol-generating material transfer component is curved about the axis of the aerosol-generating component.

[0135] C10. The article of any one of clauses C1-C9, comprising an aerosol-forming chamber.

[0136] C11. The article of clause C10, wherein the aerosol generating component is at least partially disposed in the aerosol formation chamber.

[0137] C12. The article of any one of clauses C1-C11, wherein the aerosol-generating component comprises one or more elongated openings.

[0138] C13. The article of any one of clauses C1-C12, wherein the aerosol-generating component is formed from an electrically conductive material.

[0139] C14. The article of any one of clauses C1-C13, wherein the aerosol-generating component is formed of a porous material.

[0140] C15. The article of any one of clauses C1-C14, wherein the aerosol-generating component is formed of a single layer.

[0141] C16. The article of any one of clauses C1-C15, wherein the housing defines at least one air flow channel.

[0142] C17. A non-flammable aerosol delivery system comprising an article according to any one of clauses C1-C16 and a device comprising one or more of a power source and a controller.

[0143] It will be appreciated that inventive features described above with respect to any aspect of the invention are not limited to the particular combinations described above, but are equally applicable to inventive embodiments relating to any other aspect of the invention and can be combined with them as appropriate.

[0144] Various embodiments will now be described in detail, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0145] [Figure 1] FIG. 1 is a schematic diagram of an aerosol delivery system in accordance with the present disclosure. [Diagram 2] 1 is a diagram of an article for use as part of an aerosol delivery system in accordance with the present disclosure. [Diagram 3] FIG. 3 is an exploded view of the article of FIG. 2. [Figure 4] 4A, 4B, and 4C are schematic diagrams of an exemplary aerosol generating component according to the present disclosure; [Diagram 5]Figure 5A is a schematic diagram of an exemplary aerosol generating component according to the present disclosure, Figure 5B is a schematic diagram of an exemplary aerosol generating component according to the present disclosure, Figure 5C is a schematic diagram of an exemplary aerosol generating component according to the present disclosure, and Figure 5D is a schematic diagram of an exemplary aerosol generating component according to the present disclosure. [Figure 6] 1 is a schematic diagram of an exemplary article for use as part of an aerosol delivery system in accordance with the present disclosure (although various portions of the article have been omitted for clarity); Detailed Description

[0146] In this specification, aspects and features of certain examples and embodiments are discussed / described. Some aspects and features of certain examples and embodiments may be conventionally implemented and will not be discussed / described in detail for the sake of brevity. Thus, it will be understood that unrecited aspects and features of the apparatus and methods discussed in this specification may be implemented in accordance with any conventional technology that implements such aspects and features.

[0147] As mentioned above, the present disclosure relates to, but is not limited to, non-combustion aerosol delivery systems and devices that generate aerosols from aerosol-generating materials without combustion of the aerosol-generating materials (or aerosolizable materials). Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (using a combination of aerosol-generating materials to generate aerosols). In some examples, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should also be noted that the presence of nicotine in the aerosol-generating materials is not a requirement of the present disclosure. In some examples, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system. In some examples, the non-combustion aerosol delivery system is a hybrid system that generates aerosols using a combination of aerosol-generating materials (one or more of which may be heated). Each of the aerosol-generating materials in such a hybrid system may be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some instances, a hybrid system includes liquid or gel aerosol-forming materials as well as solid aerosol-forming materials, which may include, for example, tobacco or non-tobacco products.

[0148] Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may be used, but it should be understood that these terms may be used interchangeably to refer to any non-combustible aerosol (vapor) delivery system or device as described above.

[0149] In some examples, the present disclosure relates to consumables for holding aerosol generating materials, the consumables being configured for use with non-flammable aerosol delivery devices. Throughout this disclosure, these consumables may be referred to as articles.

[0150] The non-flammable aerosol delivery system typically includes a device portion (i.e., a device) and a consumable / item portion (i.e., an item). The device portion typically includes a power source and a controller. The power source typically may be a power source (e.g., a rechargeable battery).

[0151] In some examples, the non-flammable aerosol delivery system may include an area for receiving or engaging a consumable / article, an aerosol generator (which may or may not be within the consumable / article), an aerosol generation area (which may be within the consumable / article), a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0152] In some examples, consumables / items for use with the non-flammable aerosol delivery device may include an aerosol-generating material (i.e., aerosolizable material), an aerosol-generating material storage area (i.e., a reservoir for aerosolizable material), an aerosol-generating material transfer component (i.e., a wick such as a pad), an aerosol generator (i.e., an aerosol generating component), an aerosol-generating area (i.e., an aerosol generating chamber), a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0153] The systems described herein typically generate an inhalable aerosol by vaporization of an aerosol-generating material, which may include one or more active constituents, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0154] The aerosol-generating material may be in the form of, for example, a solid, liquid, or gel, and may or may not include actives and / or flavorings. In some examples, the aerosol-generating material may include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some examples, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can hold some fluid, such as a liquid, within it. In some examples, the aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0155] The term "active substance" as used herein may relate to a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, dietary supplements, psychotropic drugs, psychoactive agents. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant.

[0156] The aerosol forming material may include one or more constituents capable of forming an aerosol. In some examples, the aerosol forming material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0157] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0158] As used herein, the term "component" is used to denote a part, portion, unit, module, assembly, or the like of an electronic cigarette or similar device, which may incorporate several smaller parts or elements, possibly within an external housing or wall. An electronic cigarette may be formed or constructed of one or more such components, which may be removably or separably connectable to one another, or may be integrally and permanently joined at the time of manufacture to define the entire electronic cigarette. The present disclosure is applicable to, but is not limited to, a system comprising two components separably connectable to one another, configured as consumable / item components, for example, capable of holding an aerosol generating material (also referred to herein as a cartridge or cartomizer), and a device / control unit having a battery for providing power to operate the elements for generating vapor from the aerosol generating material.

[0159] In this specification, aspects and features of certain examples and embodiments are discussed / described. Some aspects and features of certain examples and embodiments may be conventionally implemented and will not be discussed / described in detail for the sake of brevity. Thus, it will be understood that unrecited aspects and features of the apparatus and methods discussed in this specification may be implemented in accordance with any conventional technology that implements such aspects and features.

[0160] As mentioned above, the present disclosure relates to, but is not limited to, non-combustion aerosol delivery systems and devices that generate aerosols from aerosol-generating materials without combustion of the aerosol-generating materials (sometimes referred to herein as aerosolizable materials). Examples of such systems include e-cigarettes, tobacco heating systems, and hybrid systems (using a combination of aerosol-generating materials to generate aerosols). In some examples, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should also be noted that the presence of nicotine in the aerosol-generating materials is not a requirement of the present disclosure. In some examples, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system. In some examples, the non-combustion aerosol delivery system is a hybrid system that uses a combination of aerosol-generating materials (one or more of which may be heated) to generate aerosols. Each aerosol-forming material in such a hybrid system may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some examples, the hybrid system includes liquid or gel aerosol-forming materials as well as solid aerosol-forming materials. The solid aerosol-forming materials may include, for example, tobacco or non-tobacco products.

[0161] Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may be used, but it should be understood that these terms may be used interchangeably to refer to any non-combustible aerosol (vapor) delivery system or device as described above.

[0162] In some examples, the present disclosure relates to consumables for holding aerosol generating materials, the consumables being configured for use with non-flammable aerosol delivery devices. Throughout this disclosure, these consumables may be referred to as articles.

[0163] The non-flammable aerosol delivery system typically includes a device portion (sometimes referred to herein as a device) and a consumable / item portion (sometimes referred to herein as an item). The device portion typically includes a power source and a controller. The power source typically may be a power source (e.g., a rechargeable battery).

[0164] In some examples, the non-flammable aerosol delivery system may include an area for receiving or engaging a consumable / article, an aerosol generator (which may or may not be within the consumable / article), an aerosol generation area (which may be within the consumable / article), a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0165] In some examples, consumables / items for use with the non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area (sometimes referred to herein as a reservoir for aerosolizable material), an aerosol generating material transfer component (e.g., a wick such as a pad), an aerosol generator (sometimes referred to herein as an aerosol generating component), an aerosol generating area (sometimes referred to herein as an aerosol generating chamber), a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0166] The systems described herein typically generate an inhalable aerosol by vaporization of an aerosol-generating material, which may include one or more active constituents, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0167] The aerosol-generating material may be in the form of, for example, a solid, liquid, or gel, and may or may not include actives and / or flavorings. In some examples, the aerosol-generating material may include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some examples, the amorphous solid may be a dry gel. An amorphous solid is a solid material capable of retaining some fluid, such as a liquid, therein. In some examples, the aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0168] The term "active substance" as used herein may relate to a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, dietary supplements, psychotropic drugs, psychoactive agents. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant.

[0169] The aerosol forming material may include one or more constituents capable of forming an aerosol. In some examples, the aerosol forming material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0170] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0171] As used herein, the term "component" is used to denote a part, portion, unit, module, assembly, or the like of an electronic cigarette or similar device, which may incorporate several smaller parts or elements, possibly within an external housing or wall. An electronic cigarette may be formed or constructed of one or more such components, which may be removably or separably connectable to one another, or may be integrally and permanently joined at the time of manufacture to define the entire electronic cigarette. The present disclosure is applicable to, but is not limited to, a system comprising two components separably connectable to one another, configured as consumable / item components, for example, capable of holding an aerosol generating material (also referred to herein as a cartridge or cartomizer), and a device / control unit having a battery for providing power to operate the elements for generating vapor from the aerosol generating material.

[0172] 1 is a highly schematic diagram (not to scale) of an exemplary aerosol / vapor delivery system, such as an e-cigarette 10. The e-cigarette 10 may have a generally cylindrical shape extending along a longitudinal axis shown in dashed line, and includes two main components: a control or power component or portion 20 (sometimes referred to herein as a device), and a cartridge assembly or portion 30 (sometimes referred to herein as an article, consumable, cartomizer, or cartridge), which operates as a vapor generating component.

[0173] The cartridge assembly 30 comprises a storage compartment (sometimes referred to herein as a reservoir) 3 containing an aerosolizable material including (for example) a liquid formulation from which an aerosol containing, for example, nicotine is generated. By way of example, the aerosolizable material may include around 1-3% nicotine and 50% glycerol, with the remainder being approximately propylene glycol, but may also optionally include other ingredients such as water or flavorings. The storage compartment 3 has the form of a storage tank, a container or receptacle in which the aerosolizable material may be stored so that it is free to move and flow (if liquid) within the confines of the tank. Alternatively, the storage compartment 3 may contain a mass of absorbent material such as wadding or glass fiber that holds the aerosolizable material within its porous structure. The storage compartment 3 may be sealed after filling at the time of manufacture so as to be disposable after consumption of the aerosolizable material, or may have other openings such as an inlet port through which new aerosolizable material may be added. The cartridge assembly 30 also includes an electrical aerosol generation component 4 disposed outside the reservoir tank 3 for generating an aerosol by vaporization of the aerosolizable material. In many devices, the aerosol generation component may be a heating element (heater) that is heated by the passage of an electric current (by resistive or inductive heating) to raise the temperature of the aerosolizable material until it vaporizes. A liquid conduit arrangement such as a wick or other porous element (not shown) may also be provided to deliver the aerosolizable material from the storage compartment 3 to the aerosol generation component 4. The wick may have one or more portions disposed inside the storage compartment 3 such that the aerosolizable material may be absorbed and transferred by wicking or capillary action to other portions of the wick in contact with the aerosol generation component 4. In this way, the aerosolizable material is vaporized and replaced by new aerosolizable material transferred by the wick to the aerosol generation component 4.

[0174] The combination of the heater and wick or other arrangement of parts performing the same function may be referred to as an atomizer or atomizer assembly. Various designs are possible and the parts may be arranged differently compared to the highly schematic diagram of Figure 1. For example, the wick may be an entirely separate element from the aerosol generation component, or the aerosol generation component may be porous and configured to perform the wicking function directly (e.g., by way of a suitable electrically resistive mesh or in the form of a capillary body).

[0175] In some cases, the conduit for delivering liquid to generate vapor may be at least partially formed by one or more slots, tubes, or channels between the storage compartment and the aerosol generating component that are narrow enough to accommodate capillary action to draw and deliver the source liquid from the storage compartment for vaporization. In general, an atomizer is considered to be an aerosol generating component that can generate vapor from delivered aerosolizable material, as well as a liquid conduit (pathway) that can deliver or transport liquid from the storage compartment or similar liquid containment to the aerosol generating component by capillary forces.

[0176] Typically, the aerosol generating components are at least partially disposed within an aerosol generating chamber that forms part of the airflow channel through the e-cigarette / system, into which vapor generated by the aerosol generating components is directed and into which air flowing over and around the aerosol generating components passes, collecting the vapor generated as it condenses to form the required aerosol.

[0177] Also, referring back to FIG. 1, the cartridge assembly 30 includes a mouthpiece 35 having an opening or air outlet through which a user can inhale the aerosol generated by the aerosol generation component 4 and delivered through the air flow channel.

[0178] The power component 20 includes a cell or battery 5 (sometimes referred to herein as a battery, and which may be rechargeable) that provides power for the electrical components of the e-cigarette 10, in particular the aerosol generating component 4. There is also a printed wiring board 28 and / or other electronics or circuitry for controlling the e-cigarette generally. The control electronics / circuitry connects the vapor generating component 4 to the battery 5 when vapor is needed, for example in response to a signal from an air pressure sensor or air flow sensor (not shown) that detects a draw on the system 10, where air enters through one or more air inlets 26 in the wall of the power component 20 and flows along an air flow channel. Upon receiving power from the battery 5, the aerosol generating component 4 vaporizes the aerosolizable material delivered from the storage compartment 3 to generate an aerosol, which is then inhaled by the user through an opening in the mouthpiece 35. When the user inhales on the mouthpiece 35, the aerosol is transported to the mouthpiece 35 along an air flow channel (not shown) that connects the air inlet 26 to the air outlet. Thus, an air flow path is defined through the electronic cigarette between the air inlet(s) to the atomizer (which may or may not be present in the power component) and the air outlet in the mouthpiece. In use, the direction of airflow is from the air inlet to the air outlet along this air flow path, and therefore the atomizer can be described as being downstream of the air inlet and upstream of the air outlet.

[0179] In this particular example, the power section 20 and the cartridge assembly 30 are separate parts that are detachable from one another by separation parallel to the longitudinal axis, as shown by the solid arrow in FIG. 1. The components 20, 30 are joined together during use of the device 10 by cooperation of mating elements 21, 31 (e.g., threads, magnetic or bayonet fittings) that provide mechanical and electrical connection between the power section 20 and the cartridge assembly 30. However, this is merely an exemplary configuration, and the various components described above may be distributed differently between the power section 20 and the cartridge assembly 30, and other components and elements may be included. The two parts may be joined end-to-end in a longitudinal configuration as in FIG. 1, or may be in a different configuration, such as a parallel side-by-side arrangement. The system may or may not be generally cylindrical and / or generally longitudinal in shape. The e-cigarette 10 may be intended for disposal and replacement of one or both parts upon exhaustion (e.g., when the reservoir is empty or the battery runs out of charge), or may be intended for multiple uses, enabled by measures such as refilling the reservoir, recharging the battery, or replacing the atomizer. Alternatively, the e-cigarette 10 may be a single device (disposable or refillable / rechargeable) that cannot be separated into two or more parts, in which case all components are contained within a single body or housing. The embodiments and examples of the present invention are applicable to any of these configurations and other configurations as will be recognized by those of skill in the art.

[0180] As mentioned above, the type of aerosol generating component (such as a heating element) that may be utilized in the atomizer portion of an e-cigarette (the portion configured to generate vapor from a liquid feedstock) combines the functions of heating and liquid delivery by being both electrically conductive (resistive) and porous. However, reference to being electrically conductive (resistive) refers to a component that has the ability to generate heat in response to the flow of electric current therethrough. Such flow may be provided by so-called resistive or inductive heating. One such suitable material is an electrically conductive material such as a metal or alloy formed in sheet-like form, i.e., a planar shape whose thickness is many times smaller than its length or width. Examples in this regard include meshes, webs, grilles, and the like. Meshes may be formed of metal wires or fibers that are cohered into an integral woven or non-woven structure. For example, fibers may be cohered by sintering, where a collection of metal fibers is compressed into a single porous mass by the application of heat and / or pressure. Planar aerosol generating components may define curved surfaces, and in these cases references to the planar aerosol generating components constituting a surface refer to an imaginary plane that constitutes the surface that best fits the entire component.

[0181] These structures can provide suitable sized voids and gaps between the metal fibers to provide capillary forces for wicking of liquids. For this reason, these structures can also be considered porous, since they allow for the absorption and distribution of liquids. Furthermore, the presence of voids and gaps between the metal fibers allows air to spread through the structure. Metals are also electrically conductive and suitable for resistive heating, so heat is generated by the flow of an electric current through a material with electrical resistance. However, this type of structure is not limited to metals, and other conductive materials can be formed as fibers and configured as mesh, grill, or web structures. Examples include ceramic materials, which may or may not be doped with substances intended to adjust the physical properties of the mesh.

[0182] This type of planar sheet-like porous aerosol-generating component may be present in an aerosol-generating chamber that is arranged in an electronic cigarette to form part of an airflow channel. The aerosol-generating component may be oriented in the chamber such that the airflow through the chamber may flow in a surface direction, i.e. substantially parallel to the plane of the generally planar sheet-like aerosol-generating component. An example of such an arrangement can be found in WO 2010 / 045670 and WO 2010 / 045671, the entire contents of which are incorporated herein by reference. Thus, air can flow over the heating element and collect vapor. This makes aerosol generation very efficient. In an alternative example, the aerosol-generating component may be oriented in the chamber such that the airflow through the chamber may flow in a direction substantially transverse to the surface direction, i.e. substantially perpendicular to the plane of the generally planar sheet-like aerosol-generating component. An example of such an arrangement can be found in WO 2018 / 211252, the entire contents of which are incorporated herein by reference.

[0183] The aerosol-generating component may have one of the following structures: woven or knitted structures, mesh structures, fabric structures, open-hole fiber structures, open-hole sintered structures, open-hole foams or open-hole pile structures. Said structures are particularly suitable for achieving a high degree of porosity in the aerosol-generating component. A high degree of porosity allows for a high efficiency, since the heat generated by the aerosol-generating component is mainly used for evaporating the liquid. In said structures, porosities of more than 50% are conceivable. In one embodiment, the porosity of the aerosol-generating component is 50% or more, 60% or more, 70% or more. The open-hole fiber structure may for example consist of a nonwoven fabric, which may be optionally compressible and further improved in cohesion by sintering. The open-hole sintered structure may for example consist of a granular, fibrous or cotton-like sintered composite produced by a film casting process. The open-hole pile structure may for example be produced by a CVD process, a PVD process or flame spraying. Open-hole foams are in principle commercially available and can also be obtained in thin micro-pore designs.

[0184] In one embodiment, the aerosol-generating component has at least two layers, the layers comprising at least one of the following structures: plate, foil, paper, mesh, woven structure, fabric, open-hole fiber structure, open-hole sintered structure, open-hole foam, or open-hole stack structure. For example, the aerosol-generating component can be formed by an electric heating resistor consisting of a metal foil combined with a structure comprising a capillary structure. If the aerosol-generating component is considered to be formed by a single layer, such a layer can be formed by a woven metal wire fabric or a non-woven metal fiber fabric. Conveniently, but not necessarily, the individual layers are connected to each other by a heat treatment such as sintering or welding. For example, the aerosol-generating component may be designed as a sintered composite consisting of one or more layers of stainless steel foil and woven stainless steel wire fabric (materials, e.g., AISI 304 or AISI 316). Alternatively, the aerosol-generating component may be designed as a sintered composite consisting of at least two layers of woven stainless steel wire fabric. The layers may be connected to each other by spot welding or resistance welding. The individual layers may also be mechanically connected to each other. For example, it is also possible to produce two layers of woven wire fabric by simply folding a single layer. Instead of stainless steel, by way of example, heating conductor alloys may be used, in particular NiCr and CrFeAl alloys ("Kanthal"), which have a much higher specific electrical resistance than stainless steel. The material connection between the layers is achieved by heat treatment, so that the layers remain in contact with each other even under adverse conditions, e.g. during heating by the aerosol-generating component and the resulting induced thermal expansion. Alternatively, the aerosol-generating component may be formed by sintering a number of individual fibers together. For this reason, the aerosol-generating component may consist of sintered fibers, such as sintered metal fibers.

[0185] The aerosol generating component may comprise a thin conductive layer of an electrically resistive material, such as platinum, nickel, molybdenum, tungsten or tantalum, which is applied to the surface of the vaporizer by a PVD or CVD process or any other suitable process. In this case, the aerosol generating component may comprise an electrically insulating material (e.g. ceramic). Examples of suitable electrically resistive materials include stainless steels such as AISI 304 or AISI 316, and heating conductor alloys such as DIN material numbers 2,4658, 2,4867, 2,4869, 2,4872, 1,4843, 1,4860, 1,4725, 1,4765 and 1,4767, in particular NiCr alloys and CrFeAl alloys ("Kanthal").

[0186] As mentioned above, the aerosol generating component may be formed from a sintered metal fiber material and may be in the form of a sheet. This type of material may be considered a mesh or irregular lattice, produced by sintering together a randomly aligned configuration or array of spaced apart metal fibers or strands. It is also contemplated that a single layer of fibers may be used, or several layers (e.g. up to 5 layers). By way of example, the metal fibers may have a diameter of 8-12 μm and be configured to give a sheet of 0.16 mm thickness, weighing 100 g / m 2 ~1500g / m 2 (150g / m 2 ~1000g / m 2 , 200g / m 2 ~500g / m 2 , or 200~250g / m 2The aerosol-generating components are spaced apart to produce a material density of 0.1 mm to 0.2 mm (e.g., 0.1 mm to 0.15 mm) and a porosity of 84%. The thickness of the sheet may be in the range of 0.1 mm to 0.2 mm (e.g., 0.1 mm to 0.15 mm). Specific thicknesses include 0.10 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, or 0.1 mm. In general, the aerosol-generating component has a uniform thickness. However, as will be appreciated from the following discussion, the thickness of the aerosol-generating component does not have to be uniform. This may be due, for example, to compression of parts of the aerosol-generating component. It is also possible to vary the porosity of the aerosol-generating component by selecting different diameters and thicknesses of the fibers. For example, the aerosol-generating component may have a porosity of 66% or more, 70% or more, 75% or more, 80% or more, 85% or more, or 86% or more.

[0187] The aerosol-generating component may comprise a generally planar structure including a first and a second surface. The generally planar structure may be in the form of any two-dimensional shape (e.g., circular, semicircular, triangular, square, rectangular, and / or polygonal). Typically, the aerosol-generating component has a uniform thickness.

[0188] The width and / or length of the aerosol-generating component may be from about 1 mm to about 50 mm. For example, the width and / or length of a vaporizer may be 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In general, the width of an aerosol-generating component may be less than its length.

[0189] If the aerosol-generating component is made of an electrically resistive material, an electric current can flow through the aerosol-generating component and generate heat (so-called Joule heating). In this respect, the electrical resistance of the aerosol-generating component can be appropriately selected. For example, the aerosol-generating component may have an electrical resistance of 2 ohms or less (1.8 ohms or less, 1.7 ohms or less, 1.6 ohms or less, 1.5 ohms or less, 1.4 ohms or less, 1.3 ohms or less, 1.2 ohms or less, 1.1 ohms or less, 1.0 ohms or less, 0.9 ohms or less, 0.8 ohms or less, 0.7 ohms or less, 0.6 ohms or less, 0.5 ohms or less, etc.). The parameters of the aerosol-generating component (material, thickness, width, length, porosity, etc.) can be selected to provide the desired resistance. In this respect, a relatively low resistance can be advantageous for generating high aerosolization rates, since it is easier to draw high power from the power source. On the other hand, the resistance should not be so low as to compromise the integrity of the aerosol generator, for example the resistance may be 0.5 ohms or more.

[0190] Planar aerosol-generating components (such as heating elements) suitable for use in the systems, devices, and articles disclosed herein may be extruded or cut (such as laser cut) into the desired shape from a larger sheet of porous material. In this case, the extrusion, cutting, or removal of material may create openings in the aerosol-generating component. These openings may affect both the ability of air to pass through the aerosol-generating component and the tendency for electrical current to flow in certain areas.

[0191] FIG. 2 is a diagram of an exemplary article 100 according to the present disclosure. The article 100 comprises a housing. In this embodiment, the housing includes an outer housing 110 and an inner housing 120. The outer housing 110 is formed by the integration of first and second outer housing components 110a and 110b. The specific appearance of the outer housing 110 is not limited, but in this embodiment, it has multiple surfaces. The housing (e.g., the outer housing 110) may include at least one outlet 115. In this embodiment, there are two outlets 115. The outlet(s) 115 are for transporting the aerosol generated in the article 100 to the mouth of the user. Thus, in the embodiment shown in FIG. 2, the outer housing 110 also constitutes the mouthpiece of the article.

[0192] A first outer housing component 110a mates with a second outer housing component 110b to form the outer housing 110. In this embodiment, the components 110a, 110b fit together via a snap-fit ​​arrangement. In particular, a resilient tab 111 of the second outer housing component 110b (only one side of which is visible in FIG. 2) fits into a corresponding receiving opening 112 in the first outer housing component 110a. Of course, the exact location of the tab and opening is not limited, and in fact the tab may be formed in the outer housing component 110a and the opening may be formed in the outer housing component 110b.

[0193] Referring to FIG. 3, this figure shows the first outer housing component 110a separated from the second outer housing component 110b to reveal the inner housing component 120, the aerosol generating component 130 (which may be an electrical resistance metal heater), the flow regulator 140, and the pad 150. The inner housing component 120 may be configured to define a storage area 121 (not shown) for the aerosolizable material. The inner housing component 120 may be at least partially sleeved inside the first outer housing component 110a. Thus, the inner housing component 120 may be at least partially surrounded by the first outer housing component 110a. The inner housing component 120 may be connectable to the first outer housing component 110a (e.g., integrally attached or part of the same molding). The inner housing component 120 may have an open end 122 that engages with the flow regulator 140. The open end 122 and the flow regulator 140 may collectively define a path for the flow of aerosolizable material from the containment area 121 to the pad 150. An optional mouthpiece (not shown) may be sleeved on the outside of the first outer housing component 110a (or the outer housing may form the mouthpiece).

[0194] The flow regulator 140 may include a recess 141 into which the open end 122 of the inner housing component 120 may be received. The recess 141 may include one or more openings 142 through which the aerosolizable material may flow to the flow regulator. In this embodiment, the openings are slot-like, but it will be appreciated that one or more of the openings may have a different cross-section (such as circular, oval, or polygonal). Additionally, the cross-sectional area of ​​the opening or openings 142 may vary across the length of the flow regulator 140. Thus, the opening or openings 142 may have a larger cross-sectional area at the liquid containment area compared to the cross-sectional area at the pad 150. The flow regulator 140 may include an annular seal 143 around its periphery that helps prevent the aerosolizable material from exiting the interface between the inner housing component 120 and the flow regulator 140. The flow regulator 140 may include a surface against which the aerosol generating component 130 is biased, and which in some instances acts as a heater support.

[0195] The pad 150 may be formed of a capillary material suitable for holding the aerosolizable material. In particular, as the aerosolizable material flows through the flow regulator 140, the pad 150 may become saturated with the aerosolizable material. However, the capillary nature of the pad 150 prevents the aerosolizable material from escaping from the pad 150. The aerosol generating component 130 may be located near the pad 150 such that when the aerosol generating component 130 is provided with energy (in this embodiment, when resistively heated), the aerosolizable material present in the pad 150 is vaporized. As explained above, the pad 150 and the aerosol generating component 130 may be combined into a single component.

[0196] In this embodiment, the aerosol generation component 130 is disposed on the second outer housing component 110b. During operation of the system, electrical contacts (e.g., pins) 116 of the outer housing component 110b may contact electrical connectors (e.g., tabs) 130C of the aerosol generation component 130, thereby allowing electrical current to flow to the aerosol generation component 130.

[0197] The second outer housing component 110b may include at least one air inlet 117 to allow air to enter the article 100. In use, air enters the article 100 via the at least one air inlet 117 and mixes with the vapor generated by the aerosol generating component 130. The resulting aerosol may be directed to one or more air outlets 115 via at least one air flow channel extending between the first outer housing component 110a and the inner housing component 120. For example, in this embodiment, there are two air flow channels 180 that extend longitudinally along the length of the article 100 and cooperate with the air outlets 115 to form a flow path through the article 100.

[0198] According to one aspect, an article for use as part of a non-flammable aerosol supply system is disclosed, the article comprising: a housing having at least one air inlet; and a substantially planar aerosol generating component contained in the housing, the at least one air inlet configured to direct air in an inlet airflow direction toward the aerosol generating component, and a plane of the substantially planar aerosol generating component is angled obliquely relative to the inlet airflow direction.

[0199] It is understood that an "inlet airflow direction" refers to the direction in which air is directed through the at least one air inlet and towards the aerosol generating component. Thus, by providing an angle between the inlet airflow direction and the plane of the substantially planar aerosol generating component, the substantially planar aerosol generating component can direct air from the at least one air inlet in a particular direction through the article. In this way, the article can be manufactured with a single airflow channel, and air from the at least one air inlet can be effectively directed towards the airflow channel. This configuration can also help to reduce airflow turbulence in the at least one airflow channel, relative to when the inlet airflow direction is substantially perpendicular to the plane of the substantially planar aerosol generating component. Reducing turbulence in the at least one airflow channel can improve the quality of the generated aerosol.

[0200] In this embodiment, the article 100 may be as described above, except that the orientation of the aerosol-generating components is different. For example, in the example of Figure 2, it is seen that the plane of the substantially planar aerosol-generating component 130 is substantially perpendicular to the inlet airflow direction. In contrast, in this embodiment, the plane of the substantially planar aerosol-generating component 130 is angled obliquely to the inlet airflow direction AF, as shown diagrammatically in Figures 4A-4C.

[0201] With reference to Figure 4A, in this embodiment the plane of the substantially planar aerosol-generating component 130 is angled with respect to the inlet airflow direction AF by about 130° to about 140° (e.g., about 135°). The use of different angles is contemplated. For example, in the embodiment of Figure 4B, the plane of the substantially planar aerosol-generating component 130 is angled with respect to the inlet airflow direction AF by about 140° to about 160° (e.g., about 150°). The oblique angle is indicated as θ in Figures 4A-4C.

[0202] In some examples, the plane of the substantially planar aerosol generation component 130 is angled relative to the inlet airflow direction AF by about 100° to about 170°, about 110° to about 160°, about 120° to about 150°, or about 130° to about 140° (e.g., about 135°).

[0203] In some examples, the plane of the aerosol-generating component 130 is angled obliquely to the inlet airflow direction AF in one or more directions. This may enable the article to more effectively direct the airflow for certain configurations. In some examples, the plane of the aerosol-generating component 130 is angled obliquely to the inlet airflow direction AF in only one direction. In this regard, in the examples of Figures 4A and 4B, the plane of the aerosol-generating component 130 is angled obliquely to the inlet airflow direction AF in only one direction, i.e., along the length of the aerosol-generating component 130. In the example of Figure 4C, the plane of the aerosol-generating component 130 is angled obliquely to the inlet airflow direction AF in at least two directions, including along the length of the aerosol-generating component 130 and along the width of the aerosol-generating component 130 (the latter shown in Figure 4C).

[0204] In each of the above or all directions, the oblique angle of the plane of the substantially planar aerosol generation component 130 relative to the inlet airflow direction AF may be from about 100° to about 170°, from about 110° to about 160°, from about 120° to about 150°, or from about 130° to about 140° (e.g., about 135°).

[0205] In some examples, the housings 110 , 120 may include an aerosol formation chamber 190 .

[0206] The aerosol generation component 130 may be disposed at least partially within the aerosol formation chamber 190 .

[0207] The housings 110, 120 may define a single airflow channel 180 (the drawings do not show housings defining a single airflow channel, but one of ordinary skill in the art would understand this). In some examples, the single airflow channel 180 may extend between at least one air inlet 117 and at least one air outlet 115.

[0208] In some examples, the aerosol-generating component 130 may include one or more elongated openings 130B (e.g., as shown in FIG. 3). The aerosol-generating component 130 may comprise multiple elongated heating elements. The multiple elongated heating elements may be arranged side-by-side. The elongated openings 130B may be provided between adjacent elongated heating elements.

[0209] In some examples, the aerosol-generating component 130 may be formed of an electrically conductive material. In some examples, the aerosol-generating component 130 may be formed of a porous material. In some examples, the aerosol-generating component 130 may be formed of a single layer.

[0210] The aerosol generation component 130 may include one or more electrical connectors 130C. Multiple elongated heating elements may be provided between the electrical connectors 130C.

[0211] Article 100 may include any other features as defined herein.

[0212] Also disclosed is a non-flammable aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 comprising one or more of a power source and a controller.

[0213] System 10 may include any other features as defined herein.

[0214] According to one aspect, an article is disclosed for use as part of a non-flammable aerosol delivery system, the article comprising: an aerosol generating component; and an aerosol-generating material transfer component configured to transfer an aerosol-generating material to the aerosol generating component, wherein the aerosol generating component and the aerosol-generating material transfer component are magnetically connected to one another.

[0215] A magnetic connection can improve contact between the aerosol-generating components and the aerosol-generating material transfer components, resulting in improved aerosolization. Additionally, a magnetic connection can simplify manufacturing of the article, since the magnetic properties of the components can aid in self-alignment of the components in a desired orientation.

[0216] The magnetic coupling can be achieved in a variety of different ways. For example, the aerosol-generating component 130 and the aerosol-generating material transfer component 150 can include, consist substantially of, consist essentially of, consist of, be coated with, and / or be formed of a magnetic material. Suitable magnetic materials will be known to those skilled in the art.

[0217] In some examples, one of the aerosol generating component 130 and the aerosol-generating material transfer component 150 includes a magnetic material, and the other of the aerosol generating component 130 and the aerosol-generating material transfer component 150 includes a corresponding magnetic material. For example, one or both of the magnetic material and the corresponding magnetic material may be a permanent magnet. For example, one or both of the magnetic material and the corresponding magnetic material may be a temporary magnet or an electromagnet.

[0218] For example, the aerosol generating component 130 and the aerosol-generating material transfer component 150 may be non-permanently connected to one another. For example, the aerosol generating component and the aerosol-generating material transfer component may be releasably connected to one another. This may further simplify the process of manufacturing the article relative to a manufacturing step that would require a permanent connection of the aerosol generating component and the aerosol-generating material transfer component.

[0219] Furthermore, at least partial disassembly and reassembly of the article may be possible (eg, by a skilled technician) without permanent damage.

[0220] The article 100 may be as defined elsewhere herein, including any features thereof. For example, the aerosol generating component 130 may be substantially planar. The aerosol generating component 130 may be curved. The aerosol generating component 130 may be curved about an axis of the aerosol generating component 130. The aerosol generating material transfer component 150 may be curved about an axis of the aerosol generating component 130. The axis of the aerosol generating component 130 may correspond to a longitudinal axis of the aerosol generating component 130. The axis of the aerosol generating component 130 may correspond to a transverse (or cross) axis of the aerosol generating component 130. The axis of the aerosol generating component 130 may correspond to an axis extending between the electrical connectors 130C of the aerosol generating component.

[0221] The article 100 may include an aerosol formation chamber 130. The aerosol generation components may be at least partially disposed in the aerosol formation chamber 190.

[0222] In some examples, the aerosol-generating component 130 may include one or more elongated openings 130B (e.g., as shown in FIG. 3). The aerosol-generating component 130 may comprise a plurality of elongated heating sections. The plurality of elongated heating sections may be arranged side-by-side. The elongated openings 130B may be provided between adjacent elongated heating sections. The aerosol-generating component 130 may comprise one or more electrical connectors 130C. The elongated heating sections may be provided between the electrical connectors 130C. In some examples, the aerosol-generating component 130 is formed of an electrically conductive material. In some examples, the aerosol-generating material 130 is formed of a porous material. In some examples, the aerosol-generating component 130 is formed of a single layer.

[0223] Article 100 may include any other features as defined herein.

[0224] Also disclosed is a non-flammable aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 comprising one or more of a power source and a controller.

[0225] System 10 may include any other features as defined herein.

[0226] According to one embodiment, an aerosol generating component is disclosed that comprises at least two substantially planar portions, at least two of the substantially planar portions lying in different planes from one another.

[0227] In this configuration, the substantially planar portions that lie in different planes can help to optimally guide the airflow in the article that includes the aerosol-generating component. For example, the different planes of the portions can guide the airflow in the article in different directions. This configuration therefore allows the aerosol-generating component to be tailored to the specific design configuration of the article, thereby allowing for more effective guidance of the airflow and / or reducing or limiting turbulence in the airflow.

[0228] Features of this embodiment are illustrated diagrammatically in Figures 5A-5D. As shown, the aerosol generation component 130 comprises at least two substantially planar portions 130A', at least two of which lie in different planes.

[0229] In the example of Figures 5A-5C, the aerosol-generation component 130 comprises two substantially planar portions 130A'. In the example of Figure 5D, the aerosol-generation component 130 comprises four substantially planar portions 130A'. Of course, other numbers of heating elements 130A' may be used.

[0230] In some examples, at least two of the substantially planar portions 130A that lie in different planes define an oblique interior angle α, which may be between about 10° and about 80°, between about 20° and about 70°, between about 30° and about 60°, between about 35° and about 55°, between about 40° and about 50°, or about 45°.

[0231] In some examples, at least two ends of the substantially planar portions 130A' that lie in different planes are connected end-to-end. This configuration is shown in Figures 5A-5C, respectively. In some examples, the aerosol generation component 130 is configured such that the airflow travels perpendicular to a boundary between the at least two substantially planar portions 130A' that lie in different planes. As shown in the figures, the boundary corresponds to a straight line connecting the portions 130A'.

[0232] In some examples, at least two substantially planar portions 130A' that are in different planes define a first direction, the respective first directions being parallel to each other, and the first directions being the only parallel directions defined by the planar heating portion 130A'. For example, with reference to FIGS. 5A-5C, two substantially planar portions 130A' that are in different planes each define a first direction (along the width of the portions 130A'), the first directions being parallel to each other. No other directions are parallel to each other along each portion 130A'. Of course, various configurations are possible.

[0233] In some examples, the aerosol generation component 130 (e.g., one or all of the at least two substantially planar portions 130A') may include one or more elongated openings. For example, the aerosol generation component 130 (e.g., one or all of the at least two substantially planar portions 130A') may include multiple elongated heating portions, which may be arranged side-by-side. An elongated opening may be provided between adjacent elongated heating portions.

[0234] In some examples, the aerosol-generating component 130 is formed of an electrically conductive material. In some examples, the aerosol-generating component 130 is formed of a porous material. In some examples, the aerosol-generating component 130 is formed of a single layer.

[0235] The aerosol generation component 130 may include one or more electrical connectors 130C. The elongated heating section may be provided between the electrical connectors 130C.

[0236] Also disclosed is an article for use as part of a non-flammable aerosol supply system, comprising an aerosol generating component 130 as defined herein, and one or more of a reservoir 121 for aerosolizable material and an aerosol formation chamber 190.

[0237] The aerosol generation component 130 may be disposed at least partially within the aerosol formation chamber 190. The article 100 (e.g., the housing 110, 120) may include at least one air inlet 117 to the aerosol formation chamber 190.

[0238] The aerosol generating component 130 may be configured to direct air entering the article 100 via at least one air inlet 117 to at least two of the substantially planar portions 130A' that reside in different planes.

[0239] At least two of the substantially planar portions 130A' that lie in different planes may be configured to direct air entering the article 100 via the at least one air inlet 117 in different directions.

[0240] In instances where at least two of the substantially planar portions 130A' that lie in different planes define an oblique interior angle, the oblique interior angle may be distal from the at least one air inlet 117 with respect to the aerosol generation component 130. Such a configuration may help direct airflow in different intended directions while reducing or limiting turbulence.

[0241] In some examples, article 100 is configured such that airflow travels perpendicular to a boundary between at least two substantially planar portions 130A' that reside in different planes. As shown in the drawings, the boundary corresponds to a straight line connecting portions 130A'.

[0242] Article 100 may include any other features as defined herein.

[0243] Also disclosed is a non-flammable aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 comprising one or more of a power source and a controller.

[0244] System 10 may include any other features as defined herein.

[0245] According to one aspect, an article for use as part of a non-flammable aerosol delivery system is disclosed, the article comprising an aerosol generating component and an aerosol-generating material movement component, the aerosol generating component and the aerosol-generating material movement component being contained within a housing, and the aerosol generating component being biased relative to the aerosol-generating material movement component.

[0246] Features of this embodiment are shown diagrammatically in Figure 6. The aerosol-generating component 130 and the aerosol-generating material transfer component 150 are contained in housings 110, 120 (not shown in Figure 6). The aerosol-generating component 130 is biased against the aerosol-generating material transfer component 150. In this configuration, contact between the aerosol-generating component 130 and the aerosol-generating material transfer component is improved. For example, this configuration may facilitate improved delivery of aerosolizable material from the aerosol-generating material transfer component to the aerosol-generating component, leading to improved aerosolization.

[0247] The biasing of the aerosol generating component 130 relative to the aerosol-generating material transfer component 150 can be accomplished in a variety of ways. For example, the aerosol generating component 130 may be rigidly attached to the housing 110, 120 or a component thereof (e.g., the electrical contacts 116). For example, the aerosol-generating material transfer component 150 may be spatially constrained by the housing 110, 120 or a component thereof (e.g., the flow regulator 140). The housing and / or its component(s) may be biased relative to the aerosol generating component 130 and the aerosol-generating material transfer component 150, respectively. In this case, the aerosol generating component 130 and the aerosol-generating material transfer component 150 may be compressed together.

[0248] For example, in one embodiment, the aerosol generating component 130 is securely attached to the electrical contacts 116, which hold the aerosol generating component 130 in place within the housings 110, 120. The aerosol-generating material transfer component 150 is spatially constrained by the flow regulator 140. Furthermore, the housing 100 and its components are dimensioned such that when the article 100 is assembled, the aerosol generating component 130 biases against the aerosol-generating material transfer component 150, e.g., compressing the components 130, 150 together.

[0249] With reference to FIG. 6, the opposing arrows in FIG. 6 indicate compressive forces applied to the aerosol generating component 130 and the aerosol-generating material transfer component 150 (for clarity, other features of the article 100 are not shown). In some embodiments, the aerosol generating component is pre-biased in a particular orientation. Such pre-biasing may enable the aerosol generating component to maintain a particular degree of contact with the aerosol-generating material. In particular, if the aerosol generating component is displaced from its pre-biased state upon contact with the aerosol generating material transfer component, it may attempt to return to the pre-biased state, thereby improving contact with the aerosol generating material transfer component. In some examples, the aerosol generating component 130 is substantially planar. In some examples, the aerosol generating component 130 is curved. In some examples, the aerosol generating component 130 is curved about the axis of the aerosol generating component 130. In some examples, the aerosol generating material transfer component 150 is curved about the axis of the aerosol generating component 130. The axis of the aerosol generation component 130 may correspond to the axis between the electrical connectors 130C of the aerosol generation component 130. The axis of the aerosol generation component 130 may correspond to the longitudinal axis (or the transverse (or lateral) axis) of the aerosol generation component 130.

[0250] In some examples, the housings 110, 120 may include an aerosol-forming chamber 190. The aerosol generation component 130 may be at least partially disposed within the aerosol-forming chamber 190.

[0251] In some examples, the aerosol generating component 130 may include one or more elongated openings (e.g., as shown in FIG. 3). The aerosol generating component 130 may comprise a plurality of elongated heating sections. The plurality of elongated heating sections may be arranged side-by-side. An elongated opening may be provided between adjacent elongated heating sections. The aerosol generating component 130 may comprise one or more electrical connectors 130C. The elongated heating sections may be provided between the electrical connectors 130C. In some examples, the aerosol generating component 130 is formed of an electrically conductive material. In some examples, the aerosol generating material 130 is formed of a porous material. In some examples, the aerosol generating component 130 is formed of a single layer.

[0252] The article 100 may include at least one air flow channel 180 .

[0253] Article 100 may include any other features as defined herein.

[0254] Also disclosed is a non-flammable aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 comprising one or more of a power source and a controller.

[0255] System 10 may include any other features as defined herein.

[0256] The various embodiments described herein are presented only as aids in understanding and teaching the features of the claims. These embodiments are provided as representative samples of embodiments only and are not exhaustive and / or exclusive. The advantages, embodiments, examples, features, 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 limitations on the equivalents of the claims, and it is understood that other embodiments can be utilized and improved without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably include, consist of, or essentially consist of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. The present disclosure may also include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. An article for use as part of a non-flammable aerosol delivery system, comprising: an aerosol generating component; and an aerosol-generating material transfer component configured to transfer an aerosol-generating material to the aerosol generating component, wherein the aerosol generating component and the aerosol-generating material transfer component are magnetically connected to one another.

2. 2. The article of claim 1, wherein one of the aerosol-generating component and the aerosol-generating material transfer component comprises a magnetic material, and the other of the aerosol-generating component and the aerosol-generating material transfer component comprises a corresponding magnetic material.

3. The article of claim 2 , wherein one or both of the magnetic material and the corresponding magnetic material are permanent magnets.

4. 4. The article of claim 2 or 3, wherein one or both of the magnetic material and the corresponding magnetic material is a temporary magnet or an electromagnet.

5. The article of any one of claims 1 to 4, wherein the aerosol-generating component is substantially planar.

6. The article of any one of claims 1 to 5, wherein the aerosol generation component is curved.

7. The article of claim 6 , wherein the aerosol-generating component is curved about an axis of the aerosol-generating component.

8. The article of claim 7 , wherein the aerosol-generating material transfer component is curved about the axis of the aerosol-generating component.

9. The article of any one of claims 1 to 8, comprising an aerosol formation chamber.

10. The article of any one of claims 1 to 9, wherein the aerosol generation component is at least partially disposed in the aerosol formation chamber.

11. The article of any one of claims 1 to 10, wherein the aerosol-generating component comprises one or more elongated openings.

12. The article of any one of claims 1 to 11, wherein the aerosol generating component is formed from an electrically conductive material.

13. The article of any one of claims 1 to 12, wherein the aerosol-generating component is formed of a porous material.

14. The article of any one of claims 1 to 13, wherein the aerosol-generating component is formed in a single layer.

15. The article of any one of claims 1 to 14, wherein the aerosol-generating component and the aerosol-generating material transfer component are non-permanently connected to one another.

16. The article of any one of claims 1 to 15, wherein the aerosol-generating component and the aerosol-generating material transfer component are releasably connected to one another.

17. 17. The article of any one of claims 1 to 16, comprising a reservoir for aerosolizable material, the aerosol generating material transfer component configured to transfer aerosolizable material from the reservoir to the aerosol generating component.

18. A non-flammable aerosol delivery system comprising the article of any one of claims 1 to 17 and a device comprising one or more of a power source and a controller.

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