Supply System

Abstract

The present invention relates to an article for use in a non-combustion aerosol delivery system comprising a housing and a generally planar aerosol generating component having at least one elongated slot, the aerosol generating component being at least partially contained within the housing, the housing defining a capillary gap through which aerosolizable material can be delivered to the aerosol generating component, the capillary gap and the one, multiple, or each of the elongated slots not overlapping.

Description

Field

[0001] The present invention relates to a delivery system, in particular to a non-combustion aerosol delivery system and components of said aerosol delivery system.

[0002] Non-combustion aerosol delivery systems that generate aerosols for inhalation by a user are known in the art. Such systems typically include an aerosol generating component that can convert 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 allowed to condense into an aerosol. In other examples, the aerosol generated is an aerosol resulting from atomization of the aerosolizable material. Such atomization can be effected mechanically, for example, by subjecting the aerosolizable material to vibration to form small particles of the material that are entrained in an airflow. Alternatively, such atomization can be effected electrostatically or in other ways, such as using 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 must be considered. These characteristics may include the size of the aerosol particles, the total amount of aerosol generated, etc.

[0004] Control of 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, as a user may expect a particular sensory experience to result from use of the system.

[0005] It would be desirable to provide an aerosol delivery system with improved control of these properties.

[0006] According to a first aspect of the present disclosure, there is provided an aerosol generation component comprising at least one elongated slit, the width of the, or each, elongated slit being at most 0.3 mm.

[0007] The width of the one, the plurality of, or each elongated slit is greater than 0 mm. In some examples, the width of the one, the plurality of, or each elongated slit is up to 0.25 mm. In some examples, the width of the one, the plurality of, or each elongated slit is at least 0.05 mm, or at least 0.1 mm, or at least 0.15 mm. In some examples, the width of the one, the plurality of, or each elongated slit is between 0.05 mm and about 0.3 mm, or between 0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25 mm. In some examples, the width of the one, the plurality of, or each elongated slit is about 0.2 mm.

[0008] In some examples, the aerosol generation component is substantially planar.

[0009] In some examples, the aerosol generation component comprises a plurality of elongated slits as defined herein.

[0010] In some examples, the, or each, elongated slit includes multiple elongated slit sections.

[0011] In some examples, one, a plurality, or each elongated slit section is generally straight.

[0012] In some examples, the, a plurality of, or each elongated slit section is curved. In some examples, the curvature lies in the plane of the generally planar aerosol generation component.

[0013] In some examples, at least two of the elongated slit sections are non-parallel to one another.

[0014] In some examples, at least two of the elongated slit sections are obliquely inclined relative to one another.

[0015] In some examples, the elongated slit, or the plurality of elongated slits, is open at the periphery of the aerosol generation component.

[0016] In some examples, the elongate slit, the plurality of elongate slits, or each elongate slit is surrounded by a periphery of the aerosol generation component.

[0017] In some examples, the aerosol generation component comprises an aerosolizable material supply section configured to receive an aerosolizable material and an aerosolization section configured to aerosolize the aerosolizable material.

[0018] The aerosolization section may be characterized as a section that experiences a temperature within 50%, or within 60%, or within 70%, or within 80%, or within 90% of the maximum temperature reached by the aerosol-generating component.

[0019] In some examples, the one, the plurality, or each elongated slit is provided in the aerosolization section.

[0020] In some examples, the elongated slit, the plurality of elongated slits, or each elongated slit does not extend into the aerosolizable material supply section, in other words, the elongated slit, the plurality of elongated slits, or each elongated slit may be limited to the aerosolization section.

[0021] In some examples, one, a plurality of, or each elongate slit is connected to an elongate slot.

[0022] In some examples, the one, the plurality, or each elongated slot is provided in the aerosolization section.

[0023] In some examples, the or each elongated slot does not extend into the aerosolizable material supply section.

[0024] In some examples, the one, the plurality, or each elongated slit is provided in the aerosolizable material delivery section.

[0025] In some examples, the width of the one, the plurality, or each elongated slot is greater than 0.3 mm or at least 0.35 mm. In some examples, the width of the one, the plurality, or each elongated slot is at most 3 mm, or at most 2.5 mm, or at most 2 mm, or at most 1.5 mm, or at most 1 mm, or at most 0.8 mm, or at most 0.7 mm, or at most 0.6 mm, or at most 0.55 mm. In some examples, the width of the one, the plurality, or each elongated slot is greater than 0.3 mm and at most 1 mm, or greater than 0.3 mm and at most 0.8 mm, or greater than 0.3 mm and at most 0.6 mm, or greater than 0.3 mm and at most 0.55 mm. In some examples, the width of the, or each, elongate slot is between 0.25 mm and 1 mm, or between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or between 0.35 mm and 0.55 mm, or between 0.4 mm and 0.5 mm.

[0026] In some examples, the aerosol generation component includes one or more electrical connectors.

[0027] In some examples, the aerosol generating component is formed from a porous material.

[0028] In some examples, the aerosol generating component is formed from a conductive material. In some examples, the aerosol generating component is formed from a single layer.

[0029] In some examples, the aerosol-generating component is formed from a woven structure, a mesh structure, a woven structure, an open-pore fiber structure, an open-pore sintered structure, an open-pore foam, or an open-pore laminate structure.

[0030] In one aspect of the present disclosure, an article is provided for use as part of a non-combustion aerosol delivery system comprising an aerosol generating component according to the previous aspect of the present disclosure and one or more of an aerosol forming chamber and a reservoir for aerosolizable material.

[0031] In one aspect of the present disclosure, a non-combustion aerosol delivery system is provided comprising an article according to the previous aspect of the present disclosure and a device comprising one or more of a power source and a controller.

[0032] In one aspect of the present disclosure, an aerosol generation component is provided that includes at least one curved, elongated aperture.

[0033] In some examples, the aerosol generation component comprises a plurality of curved elongated apertures as defined herein.

[0034] In some examples, the, the plurality of, or each curved elongate aperture has an increasing curvature from one end of the aperture to the other end of the aperture.

[0035] In some examples, the, plurality of, or each curved elongate aperture is curved along at least a portion of its length. The curved aperture portion may be provided toward the periphery of the aerosol generation component. This may help reduce the occurrence of "hot spots" in undesirable locations during use. The curved aperture portion may be provided in the aerosolizable material supply section.

[0036] In some examples, the, or each, curved elongate aperture is curved along substantially its entire length.

[0037] In some examples, the aerosol generation component is substantially planar.

[0038] In some examples, the curvature of the one, the plurality, or each curved elongated aperture lies in the plane of the generally planar aerosol generation component.

[0039] In some examples, the, a plurality of, or each curved elongate aperture includes a curved portion connected to a straight portion.

[0040] In some examples, the one, the plurality, or each curved elongated aperture includes a slot portion connected to a slit portion.

[0041] In some examples, the width of the slot portion is greater than 0.3 mm.

[0042] In some examples, the width of the slot portion is greater than 0.3 mm or at least 0.35 mm. In some examples, the width of the slot portion is at most 3 mm, or at most 2.5 mm, or at most 2 mm, or at most 1.5 mm, or at most 1 mm, or at most 0.8 mm, or at most 0.7 mm, or at most 0.6 mm, or at most 0.55 mm. In some examples, the width of the slot portion is greater than 0.3 mm and at most 1 mm, or greater than 0.3 mm and at most 0.8 mm, or greater than 0.3 mm and at most 0.6 mm, or greater than 0.3 mm and at most 0.55 mm. In some examples, the width of the slot portion is between 0.25 mm and 1 mm, or between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or between 0.35 mm and 0.55 mm, or between 0.4 mm and 0.5 mm.

[0043] In some examples, the width of the slit portion is up to 0.3 mm.

[0044] The width of the slit portion is greater than 0 mm. In some examples, the slit portion has a width of up to 0.25 mm. In some examples, the width of the slit portion is at least 0.05 mm, or at least 0.1 mm, or at least 0.15 mm. In some examples, the width of the slit portion is between 0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25 mm. In some examples, the width of the slit portion is about 0.2 mm.

[0045] In some examples, the or each curved elongated aperture opens at the periphery of the aerosol generation component.

[0046] In some examples, the or each curved elongated aperture is surrounded by a periphery of the aerosol generation component.

[0047] In some examples, the aerosol generation component comprises an aerosolizable material supply section configured to receive and aerosolize an aerosolizable material, and an aerosolization section configured to aerosolize the aerosolizable material.

[0048] In some examples, the one, the plurality, or each curved elongated aperture includes a slot portion connected to a slit portion, and the one, the plurality, or each slot portion is provided in the aerosolization section.

[0049] In some examples, the one, the plurality, or each curved elongated aperture includes a slot portion connected to a slit portion, and the one, the plurality, or each slit portion is provided in the aerosolizable material supply section.

[0050] In some examples, the aerosol generation component includes one or more electrical connectors.

[0051] In some examples, the aerosol generating component is formed from a porous material.

[0052] In some examples, the aerosol generating component is formed from an electrically conductive material.

[0053] In some examples, the aerosol generating component is formed from a single layer.

[0054] In some examples, the aerosol-generating component is formed from a woven structure, a mesh structure, a woven structure, an open-pore fiber structure, an open-pore sintered structure, an open-pore foam, or an open-pore laminate structure.

[0055] In one aspect of the present disclosure, an article is provided comprising an aerosol generation component according to the previous aspect and one or more of an aerosol-forming chamber and a reservoir for aerosolizable material.

[0056] In one aspect of the disclosure, a non-combustion aerosol delivery system is provided comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0057] In one aspect of the disclosure, an article is provided for use in a non-combustion aerosol delivery system comprising a housing and a generally planar aerosol generating component having at least one elongated slot, the aerosol generating component being at least partially contained within the housing, the housing defining a capillary gap through which aerosolizable material can be delivered to the aerosol generating component, the capillary gap and the one, plurality, or each of the elongated slots do not overlap.

[0058] The substantially planar aerosol generation component may include a plurality of elongated slots as defined herein.

[0059] In some examples, the elongated slot, the plurality of elongated slots, or each elongated slot is disposed inside the capillary gap.

[0060] In some examples, the, or each, elongated slot is connected to an elongated slit to provide at least one elongated aperture.

[0061] In some examples, the or each elongate slit and the capillary gap overlap.

[0062] In some examples, the width of the one, the plurality, or each elongated slit is greater than 0 mm. In some examples, the width of the one, the plurality, or each elongated slit is up to 0.3 mm, or up to 0.25 mm. In some examples, the width of the one, the plurality, or each elongated slit is at least 0.05 mm, or at least 0.1 mm, or at least 0.15 mm. In some examples, the width of the one, the plurality, or each elongated slit is between 0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25 mm. In some examples, the width of the one, the plurality, or each elongated slit is about 0.2 mm.

[0063] In some examples, the width of the one, the plurality, or each elongated slot is greater than 0.3 mm or at least 0.35 mm. In some examples, the width of the one, the plurality, or each elongated slot is at most 3 mm, or at most 2.5 mm, or at most 2 mm, or at most 1.5 mm, or at most 1 mm, or at most 0.8 mm, or at most 0.7 mm, or at most 0.6 mm, or at most 0.55 mm. In some examples, the width of the one, the plurality, or each elongated slot is greater than 0.3 mm and at most 1 mm, or greater than 0.3 mm and at most 0.8 mm, or greater than 0.3 mm and at most 0.6 mm, or greater than 0.3 mm and at most 0.55 mm. In some examples, the width of the, or each, elongate slot is between 0.25 mm and 1 mm, or between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or between 0.35 mm and 0.55 mm, or between 0.4 mm and 0.5 mm.

[0064] In some examples, the aerosol generation component is substantially planar.

[0065] In some examples, the aerosol generation component comprises an aerosolizable material supply section configured to receive and aerosolize an aerosolizable material, and an aerosolization section configured to aerosolize the aerosolizable material.

[0066] In some examples, the slot, the plurality of slots, or each slot is provided in the aerosolization section.

[0067] In some instances, the aerosolization section and the capillary gap do not overlap.

[0068] In some examples, the aerosolization section is provided inside the capillary gap.

[0069] In some examples, the aerosolizable material supply section and the capillary gap overlap.

[0070] In some examples, the one, multiple, or each elongated slot is connected to an elongated slit to provide at least one elongated aperture, and the one, multiple, or each slit is provided in the aerosolizable material supply section.

[0071] In some examples, the housing comprises a first carrier component and a second carrier component spaced apart to define a capillary gap between the first carrier component and the second carrier component.

[0072] In some examples, the aerosol generation component includes one or more electrical connectors.

[0073] In some examples, the aerosol generating component is formed from a porous material.

[0074] In some examples, the aerosol generating component is formed from an electrically conductive material.

[0075] In some examples, the aerosol generating component is formed from a single layer.

[0076] In some examples, the aerosol-generating component is formed from a woven structure, a mesh structure, a woven structure, an open-pore fiber structure, an open-pore sintered structure, an open-pore foam, or an open-pore laminate structure.

[0077] In some examples, the article comprises one or more of an aerosol-forming chamber and a reservoir for an aerosolizable material.

[0078] In one aspect of the present disclosure, a non-combustion aerosol delivery system is provided comprising an article according to the previous aspect of the present disclosure and a device comprising one or more of a power source and a controller.

[0079] The system can be configured such that the airflow channel and / or the aerosol generation chamber and / or the aerosol generation components are separable. For example, the article may be provided in a modular form in which the airflow channel and / or the aerosol generation chamber and / or the aerosol generation components are separable.

[0080] According to another aspect of the present disclosure, there is provided:

[0081] A1. An aerosol generating component comprising at least one curved, elongated aperture.

[0082] A2. The aerosol generation component of clause A1, wherein the one, plurality, or each curved elongated aperture has an increasing curvature from one end of the aperture to the other end of the aperture.

[0083] A3. The aerosol generation component of clause A1 or A2, wherein the one, plurality, or each curved elongated aperture is curved along at least a portion of its length.

[0084] A4. An aerosol generation component according to any one of clauses A1-A3, wherein the or each curved elongated aperture is curved along substantially its entire length.

[0085] A5. The aerosol-generating component of any one of clauses A1-A4, wherein the aerosol-generating component is substantially planar.

[0086] A6. An aerosol generation component according to any one of clauses A1-A5, wherein the or each curved elongated aperture comprises a curved portion connected to a straight portion.

[0087] A7. An aerosol generation component described in any one of clauses A1-A6, wherein the one, multiple, or each curved elongated aperture includes a slot portion connected to a slit portion.

[0088] A8. An aerosol-generating component as described in clause A7, wherein the width of the slot portion is greater than 0.3 mm and the width of the slit portion is a maximum of 0.3 mm.

[0089] A9. An aerosol generating component according to any one of clauses A1 to A8, wherein the or each curved elongated aperture opens at the periphery of the aerosol generating component.

[0090] A10. An aerosol generating component according to any one of clauses A1 to A9, wherein the or each curved elongated aperture is surrounded by a periphery of the aerosol generating component.

[0091] A11. The aerosol generating component of any one of clauses A1-A10, comprising an aerosolizable material supply section configured to receive and aerosolize an aerosolizable material, and an aerosolization section configured to aerosolize the aerosolizable material.

[0092] A12. The aerosol generation component of clause A11, wherein the one, the plurality, or each curved elongated aperture comprises a slot portion connected to a slit portion, and the one, the plurality, or each slot portion is provided in the aerosolization section.

[0093] A13. The aerosol generating component of clause A11 or A12, wherein the one, the plurality, or each curved elongated aperture comprises a slot portion connected to a slit portion, and the one, the plurality, or each slit portion is provided in the aerosolizable material supply section.

[0094] A14. An aerosol generating component according to any one of clauses A1 to A13, comprising one or more electrical connectors.

[0095] A15. An aerosol-generating component according to any one of clauses A1-A14, wherein the aerosol-generating component is formed from a porous material.

[0096] A16. An aerosol-generating component according to any one of clauses A1-A15, wherein the aerosol-generating component is formed from a conductive material.

[0097] A17. An aerosol-generating component according to any one of clauses A1-A16, wherein the aerosol-generating component is formed from a single layer.

[0098] A18. An aerosol-generating component according to any one of clauses A1 to A17, wherein the aerosol-generating component is formed from a woven structure, a mesh structure, a woven structure, an open-pore fibrous structure, an open-pore sintered structure, an open-pore foam or an open-pore laminate structure.

[0099] A19. An article comprising an aerosol generation component according to any one of clauses A1-A18 and one or more of an aerosol-forming chamber and a reservoir for an aerosolizable material.

[0100] A20. A non-combustion aerosol delivery system comprising an article according to clause A19 and a device comprising one or more of a power source and a controller.

[0101] According to another aspect of the present disclosure, there is provided:

[0102] B1. An article for use in a non-combustion aerosol delivery system, comprising: a housing; and a generally planar aerosol generating component having at least one elongated slot, the aerosol generating component being at least partially contained within the housing, the housing defining a capillary gap through which aerosolizable material can be delivered to the aerosol generating component, the capillary gap and the one, plurality, or each of the elongated slots do not overlap.

[0103] B2. The article of clause B1, wherein the elongated slot, or slots, are provided inside the capillary gap.

[0104] B3. The article of clause B1 or B2, wherein the, or each, elongate slot is connected to an elongate slit to provide at least one elongate aperture.

[0105] B4. The article of any one of clauses B1-B3, wherein the one, a plurality of, or each elongate slit and the capillary gap overlap.

[0106] B5. The article of any one of clauses B1-B4, wherein the aerosol-generating component is substantially planar.

[0107] B6. The article of any one of clauses B1-B5, wherein the aerosol generation component comprises an aerosolizable material supply section configured to receive and aerosolize an aerosolizable material, and an aerosolization section configured to aerosolize the aerosolizable material.

[0108] B7. The article of clause B6, wherein the elongated slot, or slots, are provided in the aerosolization section.

[0109] B8. An article as described in clause B6 or B7, wherein the aerosolization section and the capillary gap do not overlap.

[0110] B9. The article of any one of clauses B6-B8, wherein the aerosolization section is provided inside the capillary gap.

[0111] B10. The article of any one of clauses B6-B9, wherein the aerosolizable material supply section and the capillary gap overlap.

[0112] B11. The article of any one of clauses B6-B10, wherein the one, multiple, or each elongated slot is connected to an elongated slit to provide at least one elongated aperture, and the one, multiple, or each slit is provided in the aerosolizable material supply section.

[0113] B12. The article of any one of clauses B1-B11, wherein the housing comprises a first carrier component and a second carrier component spaced apart to define a capillary gap.

[0114] B13. The article of any one of clauses B1-B12, wherein the aerosol generation component comprises one or more electrical connectors.

[0115] B14. The article of any one of clauses B1-B13, comprising one or more of an aerosol forming chamber and a reservoir for an aerosolizable material.

[0116] B15. The article of any one of clauses B1-B14, wherein the aerosol-generating component is formed from a porous material.

[0117] B16. The article of any one of clauses B1-B15, wherein the aerosol-generating component is formed from an electrically conductive material.

[0118] B17. The article of any one of clauses B1-B16, wherein the aerosol-generating component is formed from a single layer.

[0119] B18. The article of any one of clauses B1-B17, wherein the aerosol-generating component is formed from a woven structure, a mesh structure, a woven structure, an open-pore fibrous structure, an open-pore sintered structure, an open-pore foam, or an open-pore deposited structure.

[0120] B19. A non-combustion aerosol delivery system comprising an article according to any one of clauses B1-B16 and a device comprising one or more of a power source and a controller.

[0121] It will be appreciated that the features and aspects of the invention described above in relation to the first and other aspects of the invention are equally applicable to, and may be combined with, embodiments of the invention according to other aspects of the invention, as appropriate, and not just in the specific combinations described above.

[0122] 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]

[0123] [Figure 1] 1 is a schematic diagram of an aerosol delivery system according to the present disclosure. [Figure 2A] FIG. 1 is a diagram of an article for use as part of an aerosol delivery system according to the present disclosure. [Figure 2B] FIG. 2B is a diagram of a portion of the article of FIG. 2A. [Figure 2C] 2B is a cross-sectional view of the article of FIG. 2A. [Figure 2D] FIG. 2B is a front view of the article of FIG. 2A. [Figure 2E] FIG. 2B is a rear view of the article of FIG. 2A. [Figure 3A] FIG. 3 is a diagram of an exemplary aerosol-generating component for use in the article of FIG. 2. [Figure 3B] FIG. 3 is another diagram of an exemplary aerosol-generating component for use in the article of FIG. 2. [Figure 3C] FIG. 3 is yet another diagram of an exemplary aerosol-generating component for use in the article of FIG. 2. [Figure 4]FIG. 3 is a diagram of an exemplary aerosol-generating component for use in the article of FIG. 2. Detailed Description

[0124] Aspects and features of certain examples and embodiments are discussed / described herein. Some aspects and features of certain examples and embodiments may be implemented in a conventional manner and will not be discussed / described in detail for the sake of brevity. Thus, it will be understood that aspects and features of the apparatus and methods discussed herein but not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

[0125] 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 (also referred to herein as aerosolizable materials) without burning the aerosol-generating 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 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 of such a hybrid system may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some examples, hybrid systems include a liquid or gel aerosol-forming material and a solid aerosol-forming material, which may include, for example, tobacco or non-tobacco products.

[0126] Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may be used, however, it will be understood that these terms may be used interchangeably with any non-combustion aerosol (vapor) delivery system or device as described above.

[0127] In some examples, the present disclosure relates to consumables for holding aerosol generating materials and configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0128] A non-combustion aerosol delivery system typically includes a device portion (also referred to herein as a device) and a consumable / article portion (also referred to herein as an article). The device portion typically includes a power source and a controller. The power source can typically be a power source, such as a rechargeable battery.

[0129] In some examples, the non-combustion 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-generating area (which may be within the consumable / article), a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0130] In some examples, consumables / articles for use with non-combustion aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage regions (also referred to herein as reservoirs of aerosolizable material), aerosol-generating material transport components (e.g., wicks such as pads), aerosol generators (also referred to herein as aerosol-generating components), aerosol-generating regions (also referred to herein as aerosol-generating chambers), housings, wrappers, filters, mouthpieces, and / or aerosol modifiers.

[0131] The systems described herein typically generate an inhalable aerosol by vaporization of an aerosol-generating material, which may include one or more active ingredients, one or more flavors, one or more aerosol-forming materials, and / or one or more other functional materials.

[0132] The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active agent and / or flavoring. 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 may hold some fluid therein, such as a liquid. In some examples, the aerosol-generating material may include, for example, about 50%, 60%, or 70% amorphous solid by weight, up to about 90%, 95%, or 100% amorphous solid by weight.

[0133] The term "active substance" as used herein may refer to a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, psychostimulants. 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 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant.

[0134] The aerosol-forming material may include one or more components 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, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0135] 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.

[0136] As used herein, the term "component" is used to refer to a part, section, unit, module, assembly, or the like of an electronic cigarette or similar device that incorporates several smaller parts or elements that may be within an external housing or wall. An electronic cigarette may be formed or constructed from one or more such components, which may be removably or separably connectable to each other, or may be permanently joined to each other during manufacturing to define the entire electronic cigarette. The present disclosure is applicable (without being limited thereto) to a system comprising two components that are separably connectable to each other, the two components being configured, for example, as a consumable / article component (also referred to herein as a cartridge or cartomizer) that can hold an aerosol generating material, and a device / control unit having a battery for providing power to operate the elements for generating vapor from the aerosol generating material.

[0137] 1 is a highly schematic illustration (not to scale) of an exemplary aerosol / vapor delivery system, such as an e-cigarette 10. The e-cigarette 10 has a generally cylindrical shape extending along a longitudinal axis indicated by a dashed line, and comprises two main components: a control or power component or section 20 (which may be referred to herein as a device), and a cartridge assembly or section 30 (which may be referred to herein as an article, consumable, cartomizer or cartridge), which operates as a vapor generating component.

[0138] The cartridge assembly 30 includes a storage compartment 3 (also referred to herein as a reservoir) that contains an aerosolizable material that contains (for example) a liquid formulation from which an aerosol is generated, for example containing nicotine. By way of example, the aerosolizable material may contain approximately 1-3% nicotine and 50% glycerol, with the remainder being approximately propylene glycol, and possibly 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 can be stored such that the aerosolizable material is free to move and flow (if liquid) only within the tank. Alternatively, the storage compartment 3 may contain a quantity of absorbent material such as wadding or glass fiber that holds the aerosolizable material within a porous structure. The storage compartment 3 may be sealed after being filled during manufacture so that it is disposable after the aerosolizable material is consumed, or may have an inlet port or other opening through which new aerosolizable material can be added. The cartridge assembly 30 also comprises an electrical aerosol generating component 4 disposed outside the reservoir tank 3 for generating an aerosol by vaporization of the aerosolizable material. In many examples, the aerosol generating component can be a heating element (heater) that is heated by the passage of an electric current (via resistive or inductive heating) to increase the temperature of the aerosolizable material until it is vaporized. A liquid conduit arrangement such as a wick or other porous element (not shown) can be provided to deliver the aerosolizable material from the storage compartment 3 to the aerosol generating component 4. The wick may have one or more portions disposed inside the storage compartment 3 such that it can absorb the aerosolizable material and transfer it by wicking or capillary action to another portion of the wick that is in contact with the aerosol generating component 4. This aerosolizable material is thereby vaporized and replaced by new aerosolizable material transferred by the wick to the aerosol generating component 4.

[0139] The combination of a heater and wick, or other arrangement of parts that perform the same function, may be referred to as an atomizer or atomizer assembly. Various designs are possible in which the parts may be arranged differently compared to the highly schematic illustration of Figure 1. For example, the wick may be an entirely separate element from the aerosol generating component, or the aerosol generating component may be porous and configured such that it can directly perform the wicking function (e.g., by taking the form of a suitable electrically resistive mesh or capillary body).

[0140] In some cases, the conduit for delivering liquid for vapor generation may be formed at least in part from one or more slots, tubes or channels between the storage compartment and the aerosol generating component that are narrow enough to aid capillary action to draw source liquid from the storage compartment and deliver it for vaporization. In general, an atomizer can be thought of as an aerosol generating component that can generate vapor from an aerosolizable material delivered to it, and a liquid conduit (pathway) that can deliver or transport liquid from the storage compartment or similar liquid reservoir to the aerosol generating component by capillary forces.

[0141] Typically, the aerosol generating components are at least partially disposed within an aerosol generating chamber that forms part of the airflow channel through the electronic cigarette / system. Vapor generated by the aerosol generating components is forced into this chamber, and as air flows through the chamber and over and around the aerosol generating elements, the aerosol generating elements collect and condense the generated vapor to form the required aerosol.

[0142] Returning to FIG. 1, the cartridge assembly 30 also 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 airflow channel.

[0143] The power component 20 includes a cell 5 (also referred to herein as a battery, which may be rechargeable) for powering the electrical components of the e-cigarette 10, particularly the aerosol generating component 4. In addition, there is a printed circuit board 28 and / or other electronics or circuitry for overall control of the e-cigarette. The control electronics / circuitry connects the vapor generating element 4 to the battery 5 when vapor is needed, for example, in response to a signal from an air pressure or air flow sensor (not shown) that detects an inhalation on the system 10, where air enters through one or more air inlets 26 in the wall of the power component 20 to flow along an air flow channel. When the aerosol generating component 4 receives power from the battery 5, it 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. The aerosol is conveyed to the mouthpiece 35 along an air flow channel (not shown) that connects the air inlet 26 to the air outlet when the user inhales on the mouthpiece 35. Thus, an airflow path through the electronic cigarette is defined between an air inlet to the atomizer (which may or may not be in the power component) and an air outlet at the mouthpiece. In use, the airflow direction along this airflow path is from the air inlet to the air outlet, and so the atomizer can be described as being downstream of the air inlet and upstream of the air outlet.

[0144] In this particular example, the power section 20 and the cartridge assembly 30 are separate parts that can be detached from one another by separating in a direction parallel to the longitudinal axis, as shown by the solid arrow in FIG. 1. The components 20, 30 are joined together by cooperating engagement elements 21, 31 (e.g., threaded, magnetic or bayonet fittings) that provide a mechanical and electrical connection between the power section 20 and the cartridge assembly 30 when the device 10 is in use. However, this is merely an exemplary arrangement, and the various components may be distributed differently between the power section 20 and the cartridge assembly section 30, and other components and elements may be included. The two sections may be connected to one another end-to-end in a longitudinal configuration as in FIG. 1, or may be connected in a different configuration, such as a parallel side-by-side arrangement. The system may or may not be generally cylindrical and / or may have a generally longitudinal shape. Either or both sections may be intended to be disposed of and replaced when exhausted (e.g., when the reservoir is empty or the battery is dead), or may be intended to allow multiple uses by actions such as refilling the reservoir, recharging the battery, or replacing the atomizer. Alternatively, the e-cigarette 10 may be a unitary 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. Examples of the present invention are applicable to any of these configurations and other configurations as will be recognized by those skilled in the art.

[0145] As mentioned above, aerosol generating components such as heating elements of the type that can be utilized in the atomizing portion of an electronic cigarette (the portion configured to generate vapor from a source liquid) combine the functions of heating and liquid delivery by being both electrically conductive (electrically resistive) and porous. Note that references to being electrically conductive (electrically resistive) refer to components that have the ability to generate heat in response to the flow of electric current therein. Such flow can be imparted via so-called resistive or inductive heating. One example of a suitable material for this is a conductive material such as a metal or metal alloy formed in a sheet-like form, i.e., a planar shape having a thickness many times smaller than its length or width. Examples in this regard can be meshes, webs, grilles, and the like. The meshes may be formed from metal wires or fibers woven together or may be aggregated into a non-woven structure. For example, the fibers may be aggregated by sintering, in which case heat and / or pressure is applied to an assembly of metal fibers to compress them into a single porous mass. It is possible for a planar aerosol generating component to define a curved plane, and in these instances, references to a planar aerosol generating component that forms a plane refer to an imaginary flat plane that forms a best fit plane through the component.

[0146] These structures can provide suitable sized voids and gaps between the metal fibers to provide capillary forces for the wicking of the liquid. These structures can therefore also be considered porous as they provide for the uptake and distribution of liquid. Furthermore, the presence of voids and gaps between the metal fibers allows air to permeate through said structures. Metals are also electrically conductive and therefore suitable for resistive heating, whereby an electric current passing through a material with electrical resistance produces heat. However, this type of structure is not limited to metals. Other electrically conductive materials may be formed into fibers and mesh, grille or web structures. Examples include ceramic materials that may or may not be doped with substances intended to adjust the physical properties of the mesh.

[0147] This type of planar sheet-like porous aerosol-generating component may be arranged in the electronic cigarette so that it is in the aerosol-generating chamber forming part of the airflow channel. The aerosol-generating component may be oriented in the chamber so that the airflow through the chamber may flow in a surface direction, i.e., approximately parallel to the plane of the generally planar sheet-like aerosol-generating component. An example of such a configuration can be found in WO 2010 / 045670 and WO 2010 / 045671, the contents of which are incorporated herein by reference in their entirety. Thus, air can flow over the heating element and collect vapor. This makes aerosol generation very effective. In an alternative example, the aerosol-generating component may be oriented in the chamber so that the airflow through the chamber may flow in a direction generally transverse to the surface direction, i.e., approximately perpendicular to the plane of the generally planar sheet-like aerosol-generating component. An example of such a configuration can be found in WO 2018 / 211252, the contents of which are incorporated herein by reference in their entirety.

[0148] The aerosol-generating component may have and / or be formed from any one of the following structures: woven, mesh, fabric, open-pore fiber, open-pore sintered, open-pore foam or open-pore deposited. Said structures are particularly suitable for providing an aerosol-generating component with a high degree of porosity. A high degree of porosity may ensure that the heat generated by the aerosol-generating component is mainly used to evaporate the liquid, resulting in high efficiency. A porosity of more than 50% may be envisaged by said structure. In one embodiment, the porosity of the aerosol-generating component is 50% or more, 60% or more, 70% or more. The open-pore fiber structure may for example consist of a nonwoven fabric, which may optionally be compressed and further sintered to improve cohesion. The open-pore sintered structure may for example consist of a granular, fibrous or cotton-like sintered composite produced by a film casting process. The open-pore deposited structure may for example be produced by a CVD process, a PVD process or a flame spraying process. Open-pore foams are in principle commercially available and can also be obtained in thin pore designs.

[0149] In one embodiment, the aerosol-generating component is formed from a single layer. In one embodiment, the aerosol-generating component has at least two layers, the layer 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 from a single layer, such a layer may be formed from a metal wire cloth or from a non-woven metal fiber cloth. The individual layers are preferably, but not necessarily, connected to each other by a heat treatment such as sintering or welding. For example, the aerosol-generating component can be designed as a sintered composite consisting of a stainless steel foil and one or more layers of stainless steel wire cloth (e.g. AISI 304 or AISI 316 material). Alternatively, the aerosol-generating component can be designed as a sintered composite consisting of at least two layers of stainless steel wire cloth. 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, a double-layer wire fabric can be produced by simply folding a single layer. Instead of stainless steel, by way of example, heating conductor alloys can also be used, in particular NiCr and CrFeAl alloys "Kanthal", which have an even higher specific electrical resistance than stainless steel. The material connection between the layers is obtained by heat treatment, so that the layers maintain contact with each other even under adverse conditions, for example during heating by the aerosol-generating component and the resulting induced thermal expansion. Alternatively, the aerosol-generating component may be formed by sintering together a number of individual fibers. Thus, the aerosol-generating component may be composed of sintered fibers, such as sintered metal fibers.

[0150] 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 PVD or CVD or any other suitable method. In this case, the aerosol-generating component may comprise an electrically insulating material, such as a ceramic. Examples of suitable electrically resistive materials include stainless steels, such as AISI 304 or AISI 316, and heating conductor alloys, in particular NiCr 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, and the CrFeAl alloy "Kanthal".

[0151] As mentioned above, the aerosol generating component may be formed from sintered metal fiber material, and may be in the form of a sheet. This type of material can be thought of as a mesh or irregular grid, created by sintering together a randomly aligned arrangement or array of spaced apart metal fibers or filaments. A single layer of fibers, or several layers, for example up to five layers, may be used. By way of example, the metal fibers may have a diameter of 8-12 μm, arranged to give a sheet 0.16 mm thick, weighing 100 g / m 2 ~1500g / m 2 , e.g. 150g / m 2 ~1000g / m 2 , 200g / m 2 ~500g / m 2 , or 200-250g / m 2and spaced apart to produce a material density 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, it will be understood from the following description that the thickness of the aerosol generating component may vary. This may be due, for example, to some parts of the aerosol generating component being subjected to compression. Different fiber diameters and thicknesses can be selected to vary the porosity of the aerosol generating component. For example, the aerosol generating component may have a porosity of 66% or more, or 70% or more, or 75% or more, or 80% or more, or 85% or more, or 86% or more.

[0152] The aerosol generating component may form a substantially planar structure including the first and second surfaces. The substantially planar structure can take the form of any two-dimensional shape, for example, a circle, a semicircle, a triangle, a square, a rectangle, and / or a polygon. Generally, the aerosol generating component has a uniform thickness.

[0153] 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 the vaporizer may be 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm. The width may generally be less than the length of the aerosol generating component. It will be understood that the dimensions of the aerosol generating component may vary.

[0154] If the aerosol generating component is formed from an electrically resistive material, an electric current can flow through the aerosol generating component so as to generate heat (so-called Joule heating). In this regard, the electrical resistance of the aerosol generating component can be selected accordingly. For example, the aerosol generating component may have an electrical resistance of 2 ohms or less, such as 1.8 ohms or less, such as 1.7 ohms or less, such as 1.6 ohms or less, such as 1.5 ohms or less, such as 1.4 ohms or less, such as 1.3 ohms or less, such as 1.2 ohms or less, such as 1.1 ohms or less, such as 1.0 ohms or less, such as 0.9 ohms or less, such as 0.8 ohms or less, such as 0.7 ohms or less, such as 0.6 ohms or less, such as 0.5 ohms or less. The parameters of the aerosol generating component, such as the material, thickness, width, length, porosity, etc., can be selected to provide the desired resistance. In this regard, a relatively low resistance facilitates a higher power draw from the power source, which may be favorable for performing high rates of aerosolization. On the other hand, the resistance should not be so low as to compromise the integrity of the aerosol generator, for example, the resistance should not be lower than 0.5 ohms.

[0155] Planar aerosol generating components, such as heating elements, suitable for use in the systems, devices and articles disclosed herein can be formed by stamping or cutting (such as laser cutting) the required shape from a larger sheet of porous material. This can involve punching, cutting, or otherwise removing material to form openings in the aerosol generating component. These openings can affect both the ability of air to pass through the aerosol generating component and the rate at which electrical current flows through a particular area.

[0156] 2A-2C show diagrams (not to scale) of an exemplary article 100 for use in a non-combustion aerosol / vapor delivery system 10 according to the present disclosure. Generally speaking, the article 100 comprises a housing 101, 102, which may comprise a carrier assembly. The carrier assembly may comprise a first carrier component 101 and a second carrier component 102. The article 100 may comprise an aerosol-generating component 103 (see FIG. 2B). The aerosol-generating component 103 may be at least partially contained within the housing 101, 102 (e.g., within the carrier assembly). The housing (and in this example, the first and second carrier components 101, 102) serve to support the aerosol-generating component 103. Thus, for convenience, given the orientation represented in the figures, the first and second carrier components 101, 102 can also be considered as a lower platform component 101 and an upper platform component 102. The housing can define a gap G (see FIG. 2A ) through which aerosolizable material can be supplied to the aerosol generating component 103. In this example, the first carrier component 101 and the second carrier component 102 are separated by a distance d. This separation provides the gap G through which aerosolizable material can be supplied to the aerosol generating component 103 during use (e.g., from a reservoir not shown in the figure). The gap G provides capillary channels (one on each side) that extend along both sides of the aerosol generating component 103. In some examples, the aerosol generating component 103 is a substantially planar heating element 103.

[0157] The article 100 may comprise first and second electrical contact elements (e.g., corresponding first and second electrical connectors of the aerosol generating component 103) for connecting to the aerosol generating component 103. The first and second electrical contact elements may be formed from sheet metal material, including, for example, metal strips formed into an appropriate shape given the shape and configuration of the other elements of the device by conventional manufacturing techniques, or may comprise conventional flexible wiring. It will be understood that in embodiments in which electrical energy is inductively coupled to the aerosol generating component, such contact elements are not required.

[0158] The carrier assembly, e.g., the first and second carrier components 101, 102, can be molded from a plastic material having a high glass fiber content (e.g., about 50% or more) to provide improved rigidity and resistance to high temperatures, e.g., about 230 degrees Celsius.

[0159] The first and second carrier components 101, 102 may be provided in a variety of forms and dimensions. The carrier assembly is configured such that when the two carrier components 101, 102 are brought together to sandwich the aerosol generation component 103 therebetween, the carrier components 101, 102 form a carrier assembly, the airflow path 110 extends within the carrier assembly, and the aerosol generation component 103 is at least partially disposed within the carrier assembly. The airflow path 110 comprises an aerosol generation chamber. The carrier assembly may be elongated in form or have similar width and length dimensions. Additionally, the form and dimensions of the airflow path may be varied.

[0160] In the example of Figures 2A-2C, the first carrier component 101 has an upstream portion 104, a downstream portion 105 (shown in Figure 2A) and two side edges 106 (the right edge is shown in Figure 2A). As shown in Figures 2B and 2C, the second carrier component 102 has an upstream portion 107, a downstream portion 108 and two side edges 109. The first carrier component 101 and the second carrier component 102 have approximately the same width (measured from side edge to side edge). An air inlet 113 is provided in the upstream portion 104 of the first carrier component 101 (see Figure 2C) and an air outlet 114 is provided in the downstream portion 108 of the second carrier component 102 (see Figures 2B and 2C). In particular, it can be seen from Figure 2C that in use, air flows into the air inlet 113, along the air flow path 110 and through the outlet 114.

[0161] The first carrier component 101 and the second carrier component 102 may be attached to one another by any suitable means, such as a clearance fit, an intermediate fit, or an interference fit. Other attachments are also envisioned. In some examples, for example in the particular example of FIG. 2, the first carrier component 101 and the second carrier component 102 may be attached to one another by a snap fit. For example, one or more of the first carrier component 101 and the second carrier component 102 may include one or more protrusions configured to engage (e.g., via a snap fit) with a corresponding portion of the other of the first carrier component 101 and the second carrier component 102. 2A-2E, the first carrier component 101 comprises a pair of protrusions 120 disposed towards its downstream portion 105, which are configured to engage with corresponding ledges 121 of the second carrier component 102 via a snap fit, and the second carrier component 102 comprises a protrusion 122 disposed on its upstream portion 107, which is configured to engage with corresponding ledges 123 of the first carrier component 101 via a snap fit. It will be appreciated that the manner of attachment between the first carrier component 101 and the second carrier component 102 may be varied.

[0162] The aerosol-generating component 103 may be formed from a porous material. For example, the aerosol-generating component 103 may be formed from a conductive material. For example, the aerosol-generating component 103 may be formed from a single layer. For example, the aerosol-generating component 103 may be formed from a woven structure, a mesh structure, a woven structure, an open-pore fiber structure, an open-pore sintered structure, an open-pore foam, or an open-pore stacked structure. For example, the aerosol-generating component 103 may be generally in the form of a sheet. For example, the aerosol-generating component 103 may be formed from a sintered metal fiber material, generally in the form of a sheet. It will be appreciated that other porous conductive materials may be used as well.

[0163] For example, the aerosol generation component 103 may include a main portion having electrical connectors for connecting to the respective electrical contacts. For example, the main portion of the aerosol generation component may be generally rectangular with a longitudinal dimension (i.e., in the direction passing between the electrical contact extensions 103B) of about 20 mm and a width of about 8 mm. Other dimensions are also envisioned.

[0164] For example, the longitudinal dimension may correspond to the direction of airflow through the vaporization chamber (note that in other examples, the longitudinal dimension need not be the longest dimension of the aerosol generating component 103). The thickness of the sheet including the aerosol generating component 103 may be about 0.15 mm. Other dimensions are envisioned.

[0165] The aerosol generation component 103 may include one or more apertures 200 (e.g., elongated apertures). In some examples, the apertures 200 may include one or more elongated apertures extending inward from each of the long sides (sides parallel to the longitudinal direction). For example, the elongated apertures 200 may extend inward by about 4.8 mm. For example, the inwardly extending elongated apertures may be separated from each other by about 5.4 mm on each side of the aerosol generation component 103, with the slots extending inward from the opposing sides being offset from each other by about half of this spacing. In other words, the slots may be arranged alternately along the longitudinal sides. Other configurations and dimensions are also envisioned. As a result of this arrangement of the slots 200 in the aerosol generation component 103, the flow of current along the aerosol generation component 103 is in effect forced to follow a serpentine path, resulting in a concentration of current, and therefore power, around the ends of the slots. In this regard, and due to the presence of the elongated aperture, the aerosol generation component 103 can be configured such that some regions of the aerosol generation component 103 (in this example, a tortuous path) receive a greater proportion of current than other regions.

[0166] By having the current follow a serpentine path, a greater number of high temperature regions (also called "hot spots") are distributed more evenly across the aerosol-generating component 103, as opposed to having the current follow a direct path resulting in fewer and larger high temperature regions that are less evenly distributed across the aerosol-generating component 103. In this way, the risk of combustion of the aerosolizable material and / or unintended drying of the aerosol-generating component 103 can be reduced. Also, a more uniform heat distribution, and therefore a more consistent aerosolization (e.g., more consistent particle size), can be achieved.

[0167] In some examples (see, for example, Figures 3A-3C), the aerosol-generating component 103 is rotationally symmetric about an axis passing through the centre of, and perpendicular to, the plane of the aerosol-generating component 103.

[0168] Those skilled in the art will appreciate that article 100 can be manufactured in a variety of different ways, and the examples described herein serve as representative. For example, the manner in which aerosol-generating component 103 is disposed within a housing, e.g., between second carrier component 102 and first carrier component 101, may be varied.

[0169] In the example of Figures 2A-2E, the article 100 includes carrier assemblies 101, 102 having an air flow path 110 that, when assembled into an aerosol generation system 10 (e.g., an electronic cigarette), includes an aerosol generation chamber, the air flow path 110 extending between an air inlet and an air outlet of a mouthpiece within the system 10.

[0170] It will be appreciated that in use, the article 100 of FIG. 2 may be surrounded on both sides by a reservoir (not shown) for the aerosolizable material. As explained, the distance between the first carrier component 101 and the second carrier component 102 corresponds to the gap G. This gap G is in fluid communication with the reservoir and provides capillary channels (one on each side) that extend along each side of the aerosol generation component 103. For example, in use, the aerosolizable material is fed through the gap G and enters the pores (if present) of the aerosol generation component 103 for vaporization, generating a vapor in the aerosol generation chamber. The passing air collects the vapor and generates an aerosol, which is drawn from the aerosol generation chamber, along a further portion of the airflow path through the system 10, and out the air outlet.

[0171] When installed in an electronic cigarette 10, the article 100 may be positioned such that a longitudinal direction of the aerosol generating component 103, which corresponds to the direction of airflow through the article 100 from the upstream end to the downstream end, is aligned parallel to the longitudinal axis of the electronic cigarette 10 for an end-to-end system such as the example of Figure 1, or at least parallel to the longitudinal axis of the device in a side-by-side system in which the device is disposed to the side of the article 100. However, this is not required, and as used herein, the term "longitudinal" is intended to refer to the dimensions and orientation of the atomizer, and in particular the dimensions of the aerosol generating component along the airflow path from the atomizer inlet at the upstream end of the atomizer, through the vaporization chamber, to the atomizer outlet at the downstream end of the atomizer.

[0172] Exemplary aspects of the present disclosure will now be described.

[0173] According to one aspect of the present disclosure, an aerosol generating component is disclosed, comprising at least one elongated slit, the width of one, the plurality of, or each elongated slit being at most 0.3 mm. The inventors have determined that the use of slots (wider than the slits in this context) that can be found in prior art aerosol generating components can result in unintended leakage of aerosolizable material through the slots. In particular, said slots can act as leakage paths for aerosolizable material. The inventors have determined that the use of slits having a width narrower than the slots can reduce the risk of unintended leakage of aerosolizable material through the aerosol generating component. At the same time, the use of slits can provide additional current paths and thus result in uniform heat distribution across the aerosol generating component. In this way, a more consistent particle size and therefore improved aerosolization can be achieved.

[0174] 3A-3C and 4 show an exemplary aerosol generation component 103 including at least one elongated slit 200 (not all numbered for clarity). In this embodiment, the width of the elongated slit 200, or each elongated slit 200, is up to 0.3 mm. As discussed above, this width is effective to reduce the risk of leakage of aerosolizable material while providing effective heating and heat distribution.

[0175] The width of the one, the plurality of, or each elongated slit 200 is greater than 0 mm. In some examples, the width of the one, the plurality of, or each elongated slit 200 is up to 0.25 mm. In some examples, the width of the one, the plurality of, or each elongated slit 200 is at least 0.05 mm, or at least 0.1 mm, or at least 0.15 mm. In some examples, the width of the one, the plurality of, or each elongated slit 200 is between 0.05 mm and about 0.3 mm, or between 0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25 mm. In some examples, the width of the one, the plurality of, or each elongated slit 200 is about 0.2 mm. A width of about 0.2 mm has been found to be particularly effective in reducing the risk of unintended leakage of aerosolizable material.

[0176] In some examples, one, a plurality, or each of the elongated slits 200 is substantially straight, for example, in the example of Figures 3A and 3B, each of the elongated slits 200 is substantially straight.

[0177] In some examples, the or each elongate slit is curved.

[0178] In some examples, the aerosol generation component 103 is substantially planar. Although this configuration is shown in the figures, it will be understood that different geometries are contemplated.

[0179] It will also be appreciated that the configuration of the or each elongate slit 200 may vary. In some examples, one, more, or each elongate slit 200 includes multiple elongate slit sections. In some examples, one, more, or each elongate slit section is generally straight. In some examples, one, more, or each elongate slit section is curved (e.g., in the plane of the generally planar aerosol generation component 103, as shown in FIG. 4).

[0180] In some examples, at least two of the elongated slit sections are inclined relative to one another. In some examples, at least two of the elongated slit sections may be non-parallel to one another. In some examples, at least two of the elongated slit sections are inclined at an angle relative to one another. For example, as shown in FIG. 3C, two of the elongated slits 200 each include two slit sections that are inclined relative to one another.

[0181] In some examples, the elongated slit 200, or each elongated slit 200, opens at the periphery of the aerosol generating component 103. This configuration is shown, for example, in Figures 3B, 3C, and 4, i.e., in each of Figures 3B, 3C, and 4, two slits 200 open at the periphery of the aerosol generating component 103. Advantageously, this configuration helps to provide an area of ​​higher current density, but is unlikely to result in unintended leakage of aerosolizable material.

[0182] In some examples, one, a plurality, or each of the elongated slits 200 are surrounded by the periphery of the aerosol generation component. This configuration is shown, for example, in Figures 3A, 3C, and 4, where several elongated slits 200 are surrounded by the periphery of the aerosol generation component 103. By surrounding the elongated slits 200, the elongated slits 200 are less likely to form a leakage path for aerosolizable material.

[0183] The aerosol-generation component 103 may include (e.g., at least one) aerosolizable material supply section 103F configured to receive (e.g., by capillary forces) an aerosolizable material. The aerosolizable material supply section 103F is shown, for example, in FIG. 4, where the sections outside the respective dashed lines correspond to the aerosolizable material supply section 103F.

[0184] The aerosol generation component 103G may comprise (e.g., at least one) aerosolization section 103G configured to aerosolize an aerosolizable material. The aerosolization section 103G is shown, for example, in FIG. 4, where the sections defined between the respective dashed lines correspond to the aerosolization section 103G. It should be understood that, in use, only the aerosolization section 103G may reach a temperature sufficient to aerosolize the aerosolizable material.

[0185] In some examples, the aerosol generating component 103 has a porous and / or permeable structure that allows the aerosolizable material to enter. Thus, in some examples, the aerosol generating component 103 can entrap aerosolizable material such that the aerosolizable material is fed from the aerosolizable material feed section 103F to the aerosolization section 103F to be aerosolized.

[0186] In some examples, one, a plurality, or each elongated slit 200 is provided in the aerosolization section 103G.

[0187] In some examples, the elongated slit 200 is provided in the aerosolization section 103G. In some examples, the elongated slit 200 does not extend into the aerosolizable material supply section 103F. By providing the slit in this manner, the risk of unintended leakage of the aerosolizable material is reduced. At the same time, the slit provides an additional current path to provide additional hot spots. As the total number of hot spots increases and the intensity of each hot spot decreases, the heat distribution across the aerosol generating components is improved. This can result in a more consistent particle size and therefore improved aerosolization.

[0188] In some examples, one, a plurality, or each elongated slit 200 is connected to an elongated slot 201. In such examples, the elongated slits 200 connected to the elongated slots 201 may form an elongated aperture. In such examples, the slits 200 and the slots 201 may be referred to as a "slit portion" 200 and a "slot portion" 201, respectively.

[0189] It should be understood that slits and slots are forms of apertures. It should also be understood that a slot is wider than a slit.

[0190] In some examples, the width of the one, the plurality, or each elongated slot 201 is greater than 0.3 mm or at least 0.35 mm. In some examples, the width of the one, the plurality, or each elongated slot 201 is at most 3 mm, or at most 2.5 mm, or at most 2 mm, or at most 1.5 mm, or at most 1 mm, or at most 0.8 mm, or at most 0.7 mm, or at most 0.6 mm, or at most 0.55 mm. In some examples, the width of the one, the plurality, or each elongated slot 201 is greater than 0.3 mm and at most 1 mm, or greater than 0.3 mm and at most 0.8 mm, or greater than 0.3 mm and at most 0.6 mm, or greater than 0.3 mm and at most 0.55 mm. In some examples, the width of the, or each, elongated slot 201 is between 0.25 mm and 1 mm, or between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or between 0.35 mm and 0.55 mm, or between 0.4 mm and 0.5 mm.

[0191] In some examples, the one, the plurality, or each of the elongated slits 200 is provided in the aerosolizable material supply section 103F. In some examples, the one, the plurality, or each of the elongated slots 201 is provided in the aerosolization section 103G. Thus, the use of the slits 200 in the aerosolizable material supply section 103F reduces the risk of leakage of the aerosolizable material (compared to the use of slots). Also, the use of the slits 200 in the aerosolizable material supply section 103F can increase the storage amount of the aerosolizable material in the aerosol generating component 103 (compared to the use of slots) since less material is removed from the aerosol generating component 103 (compared to the use of slots). Furthermore, the use of the slits 200 in the aerosolizable material supply section obviates the need for a means to prevent leakage of the aerosolizable material through the slits. In contrast, in some aerosol generating components in which a slot extends through the aerosolizable material supply section (and, for example, to the periphery of the aerosol generating component), means may be required to prevent leakage of aerosolizable material through the slot.

[0192] In some examples, one, a plurality, or each elongated slit 200 extends within the aerosolization section.

[0193] 4, elongated slits 200 are connected to respective elongated slots 201 to form respective elongated apertures. Elongated slits 200 are disposed (at least partially) in aerosolizable material supply section 103F, and elongated slots 201 are disposed in aerosolization section 103G.

[0194] It will be appreciated that in some embodiments, the elongated slot 201 may taper into the slit 200. It will also be appreciated that different configurations of the slit 200 and slot 201 are envisioned.

[0195] The aerosol generation component 103 may include one or more electrical connectors 103C. The aerosolization section may be provided between the electrical connectors 103C.

[0196] The aerosol-generating component may include any other feature defined herein.

[0197] Also disclosed is an article 100 for use as part of a non-combustion aerosol delivery system 10 comprising an aerosol generating component 103 as defined herein and one or more of an aerosol forming chamber 190 and a reservoir 121 for aerosolizable material.

[0198] Also disclosed is a non-combustion aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 that includes one or more of a power source and a controller.

[0199] System 10 may include any other features defined herein.

[0200] According to one embodiment, an aerosol generating component is disclosed that includes at least one curved elongated aperture. Due to its curved shape, the aperture can encompass a larger surface area (for a given length) relative to a straight elongated aperture. In this manner, the use of at least one curved elongated aperture can improve the amount and / or distribution of aerosol generation. For example, aerosol can be generated over an increased surface area.

[0201] By "curved" it is to be understood that the at least one curved elongate aperture is at least partially curved. That is, the at least one curved elongate aperture does not necessarily have to be curved along its entire length, but may include partial curvatures (as well as, for example, straight sections). The curved aperture section may be provided towards the periphery of the aerosol generation component. This may help to reduce the occurrence of "hot spots" in undesirable locations in use. The curved aperture section may be provided in the aerosolizable material supply section.

[0202] 4, the aerosol generation component 103 includes at least one curved, elongated aperture 200, 201. In some examples, one, a plurality of, or each curved, elongated aperture 200, 201 has an increasing curvature from one end of the aperture 200, 201 to the other end of the aperture 200, 201. The increasing curvature may be continuous. The increasing curvature may begin midway along the aperture 200, 201.

[0203] In some examples, one, more than one, or each curved elongate aperture 200, 201 is curved along at least a portion of its length.

[0204] In some examples, one, more, or each curved elongate aperture 200, 201 is curved along substantially its entire length.

[0205] In some examples, the aerosol generation component 103 is substantially planar.

[0206] In some examples, the one, the plurality, or each curved elongated aperture 200, 201 has a substantially constant width.

[0207] In some examples, one, more, or each curved elongated aperture 200, 201 includes a curved portion (or at least a partially curved portion) connected to a generally straight portion.

[0208] 4, there are four apertures 200, 201. Two of the apertures 200, 201 each include an at least partially curved portion 201 connected to a generally straight portion 200. Another two of the apertures 200, 201 each include an at least partially curved portion 200 connected to a generally straight portion 201.

[0209] In some examples, one, multiple, or each curved elongated aperture 200, 201 includes a slot portion 201. In some examples, one, multiple, or each curved elongated aperture 200, 201 includes a slit portion 200. In some examples, one, multiple, or each curved elongated aperture 200, 201 includes a slot portion 201 connected to a slit portion 200. It should be understood that the slot portion 201 has a greater width than the slit portion 200.

[0210] It should be understood that the slot portion (also referred to as a "slot") is wider than the slit portion (also referred to as a "slit").

[0211] In some examples, the width of the slot portion is greater than 0.3 mm. In some examples, the width of the slot portion is at least 0.35 mm. In some examples, the width of the slot portion is at most 3 mm, or at most 2.5 mm, or at most 2 mm, or at most 1.5 mm, or at most 1 mm, or at most 0.8 mm, or at most 0.7 mm, or at most 0.6 mm, or at most 0.55 mm. In some examples, the width of the slot portion is greater than 0.3 mm and at most 1 mm, or greater than 0.3 mm and at most 0.8 mm, or greater than 0.3 mm and at most 0.6 mm, or greater than 0.3 mm and at most 0.55 mm. In some examples, the width of the slot portion is between 0.25 mm and 1 mm, or between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or between 0.35 mm and 0.55 mm, or between 0.4 mm and 0.5 mm.

[0212] In some examples, the width of the slit portion is up to 0.3 mm. The width of the slit portion is greater than 0 mm. In some examples, the slit portion has a width of up to 0.25 mm. In some examples, the width of the slit portion is at least 0.05 mm, or at least 0.1 mm, or at least 0.15 mm. In some examples, the width of the slit portion is between 0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25 mm. In some examples, the width of the slit portion is about 0.2 mm.

[0213] It should be understood that the joints / connections between each slot portion 201 and each slit portion 200 may be of various widths intermediate the slot portion 201 and the slit portion 200 .

[0214] The aerosol generation component 103 may include a plurality of curved, elongated apertures, each of which may be as defined herein.

[0215] In some examples, the or each curved elongated aperture 200, 201 opens at the periphery of the aerosol generation component 103. As shown in Figure 4, two of the apertures 200, 201 open at the periphery of the aerosol generation component 103.

[0216] In some examples, the, or each, curved elongated aperture 200, 201 is surrounded by a periphery of the aerosol generation component 103. As shown in FIG. 4, two of the apertures 200, 201 are surrounded by a periphery of the aerosol generation component 103.

[0217] In some examples, the aerosol generation component 103 comprises an aerosolizable material supply section 103F configured to receive aerosolizable material (eg, by capillary forces).

[0218] In some examples, the aerosol generation component 103 comprises an aerosolization section 103G configured to aerosolize an aerosolizable material.

[0219] In some examples, one, more than one, or each slot portion 201 is provided in the aerosolization section 103G. In some examples, one, more than one, or each slot portion 201 does not extend into the aerosolizable material supply section 103F.

[0220] In some examples, one, more than one, or each slit portion 200 is provided within the aerosolizable material supply section 103F. In some examples, one, more than one, or each slit portion 200 extends into the aerosolization section.

[0221] 4, each slot portion 201 is provided in aerosolization section 103G, two slit portions 200 are provided in aerosolizable material supply section 103F and extend into aerosolization section 103G, and two slit portions 200 are provided substantially entirely within aerosolizable material supply section 103F. Variations on this configuration are also envisioned.

[0222] In some examples, the aerosol generation component 103 includes one or more electrical connectors 103C. The aerosolization section 103G can be provided between the electrical connectors 103C.

[0223] The aerosol generating component 103 may include any other features defined herein.

[0224] Also disclosed is an article 100 for use as part of a non-combustion aerosol delivery system 10 comprising an aerosol generating component 103 as defined herein and one or more of an aerosol forming chamber and a reservoir for aerosolizable material.

[0225] Article 100 may be configured such that aerosolizable material can be supplied from a reservoir via aerosolizable material supply section 103F to aerosolization section 103G.

[0226] Also disclosed is a non-combustion aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 that includes one or more of a power source and a controller.

[0227] System 10 may include any other features defined herein.

[0228] According to one aspect, an article is disclosed for use in a non-combustion aerosol delivery system comprising a housing and an aerosol generating component having at least one elongated slot, the aerosol generating component being at least partially contained within the housing, the housing defining a capillary gap through which aerosolizable material can be delivered to the aerosol generating component, the capillary gap and the one, multiple, or each elongated slot do not overlap.

[0229] By providing a non-overlapping elongated slot and capillary gap, the likelihood of leakage of aerosolizable material through the elongated slot is reduced, for example, leakage of aerosolizable material may be more pronounced if the capillary gap coincides or overlaps with the elongated slot.

[0230] In some examples, the elongated slot 201 is disposed inside the capillary gap. In this manner, the elongated slot 201 is disposed away from the capillary gap and toward the center of the aerosol generation element 103. This configuration further reduces the risk of leakage of the aerosolizable material.

[0231] In some examples, the capillary gap provides a capillary channel that coincides with and / or overlaps the periphery of the aerosol generation component 103. In some examples, the capillary gap provides a capillary channel that coincides with and / or overlaps a side edge of the aerosol generation component 103. In some examples, the capillary gap provides two capillary channels that coincide with and / or overlap each side edge of the aerosol generation component 103.

[0232] In some examples, the elongated slot 201, or each elongated slot 201 forms part of an elongated aperture of the aerosol generation component 103 (in which case the elongated slot may be referred to as an "elongated slot portion"). Thus, the aerosol generation component 103 may include at least one elongated aperture having at least one elongated slot 201.

[0233] In some examples, the aerosol generation component 103 includes at least one elongated slit 200. In some examples, one, a plurality of, or each elongated slit 200 may form part of an elongated aperture of the aerosol generation component 103 (in which case the elongated slit may be referred to as an "elongated slit portion").

[0234] In some examples, one, a plurality, or each elongated slot 201 is connected to an elongated slit 200. This may be such as to form an elongated aperture 200, 201. Such a configuration is shown in FIG. 4 and described elsewhere herein.

[0235] In some examples, the elongated slit(s) 200 and the capillary gap overlap and / or coincide. Providing an elongated slit in this location can provide an additional current path, increased resistance, and improved heating while maintaining a reduced risk of leakage through the aerosol generation component 103.

[0236] The or each elongate slot 200 and the or each elongate slit 200 may be as defined elsewhere herein.

[0237] In some examples, the aerosol generation component 103 comprises an aerosolizable material supply section 103F configured to receive aerosolizable material (eg, by capillary forces).

[0238] In some examples, the aerosol generating component 103 comprises an aerosolization section 103G configured to aerosolize the aerosolizable material. In some examples, the aerosol generating component 103 is substantially planar. The substantially planar aerosol generating component 103 may include a plurality of elongated slots 201 as defined herein.

[0239] Aerosolizable material supply section 103F and aerosolization section 103G can be as described elsewhere herein.

[0240] In some examples, one, a plurality, or each elongated slot 201 is provided in the aerosolization section 103F.

[0241] In some examples, one, a plurality, or each elongated slit 200 is provided in aerosolizable material supply section 103G.

[0242] In some instances, the aerosolization section 103G and the capillary gap do not overlap.

[0243] In some instances, aerosolizable material supply section 103F and the capillary gap overlap.

[0244] It will be appreciated that the housing may be provided in various forms. For example, the housing may comprise a carrier assembly. The housing, e.g., carrier assembly, may comprise a first carrier component 101 and a second carrier component 102. The first carrier component 101 and the second supported carrier component 102 may define a capillary gap. For example, the capillary gap may be defined by a spacing between the first carrier component 101 and the second carrier component 102, e.g., when the first carrier component 101 and the second carrier component 102 are attached to one another. The aerosol generation component 103 may be at least partially disposed between the first carrier component 101 and the second carrier component 102. The first carrier component 101 and the second carrier component 102 may be as described elsewhere herein.

[0245] In some examples, the aerosol generation component 103 includes one or more electrical connectors 103C. The aerosolization section 103G can be provided between the electrical connectors 103C.

[0246] Article 100 may include one or more of an aerosol-forming chamber and a reservoir for an aerosolizable material.

[0247] Article 100 may be configured such that aerosolizable material can be supplied from a reservoir via aerosolizable material supply section 103F to aerosolization section 103G.

[0248] Also disclosed is a non-combustion aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 that includes one or more of a power source and a controller.

[0249] System 10 may include any other features defined herein.

[0250] The drawings herein are schematic and not drawn to scale. Various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments can be utilized and modifications can be made without departing from the scope of the claimed invention. Various embodiments of the invention can suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Moreover, the present disclosure can include other inventions not currently claimed but which may be claimed in the future.

Claims

1. An article for use in a non-combustion aerosol delivery system comprising a housing and a generally planar aerosol generating component having at least one elongated slot, the aerosol generating component being at least partially contained within the housing, the housing defining a capillary gap through which aerosolizable material can be delivered to the aerosol generating component, the capillary gap and the one, plurality, or each elongated slot do not overlap.

2. The article of claim 1 , wherein the or each elongated slot is disposed inside the capillary gap.

3. 3. The article of claim 1 or 2, wherein the or each elongated slot is connected to an elongated slit to provide at least one elongated aperture.

4. The article of any one of claims 1 to 3, wherein the or each elongate slit and the capillary gap overlap.

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 comprises an aerosolizable material supply section configured to receive and aerosolize an aerosolizable material, and an aerosolization section configured to aerosolize the aerosolizable material.

7. The article of claim 6 , wherein the or each elongated slot is provided in the aerosolization section.

8. The article of claim 6 or 7, wherein the aerosolization section and the capillary gap do not overlap.

9. The article of any one of claims 6 to 8, wherein the aerosolization section is provided inside the capillary gap.

10. The article of any one of claims 6 to 9, wherein the aerosolizable material supply section and the capillary gap overlap.

11. 11. The article of any one of claims 6 to 10, wherein the one, multiple, or each elongated slot is connected to an elongated slit to provide at least one elongated aperture, and the one, multiple, or each slit is provided in the aerosolizable material supply section.

12. The article of any one of claims 1 to 11, wherein the housing comprises a first carrier component and a second carrier component spaced apart to define the capillary gap.

13. The article of any one of claims 1 to 12, wherein the aerosol generation component comprises one or more electrical connectors.

14. The article of any one of claims 1 to 13, comprising one or more of an aerosol formation chamber and a reservoir for aerosolizable material.

15. The article of any one of claims 1 to 14, wherein the aerosol-generating component is formed from a porous material.

16. The article of any one of claims 1 to 15, wherein the aerosol-generating component is formed from an electrically conductive material.

17. The article of any one of claims 1 to 16, wherein the aerosol-generating component is formed from a single layer.

18. The article of any one of claims 1 to 17, wherein the aerosol-generating component is formed from a woven structure, a mesh structure, a woven structure, an open-pore fiber structure, an open-pore sintered structure, an open-pore foam, or an open-pore deposited structure.

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

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