Supply System

Abstract

An article (100) for use as part of a non-combustion aerosol delivery system (10), comprising a housing (101) having a first section (102) and a second section (103) that together form a reservoir (104) for an aerosolizable material (200), the first section and the second section connected to one another to provide at least one pair of opposing surfaces (106, 108 and 107, 109), a capillary channel (110) provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature (111) for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel.

Description

[Technical field]

[0001] The present invention relates to a delivery system, and more particularly to an article for use as part of a non-combustion aerosol delivery system, a non-combustion aerosol delivery system including the article, and a method of making the article. [Background technology]

[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 generator capable of converting an aerosolizable material into an aerosol. In some examples, the aerosol generated is a condensation aerosol, where the aerosolizable material is first vaporized and then allowed to condense into an aerosol. In other examples, the aerosol generated is an aerosol resulting from atomization of the aerosolizable material. Such atomization may be effected mechanically, for example, by subjecting the aerosolizable material to vibration to form small particles of the material that are entrained in an airflow. Alternatively, such atomization may 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 properties 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 the 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 over these properties. Summary of the Invention

[0006] According to a first aspect of the present disclosure, an article is provided for use as part of a non-combustion aerosol delivery system comprising a housing having a first section and a second section that together form a reservoir for an aerosolizable material, the first section and the second section connected to one another to provide at least one pair of opposing surfaces, a capillary channel being provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel.

[0007] One of the first section and the second section may at least partially surround the other of the first section and the second section.

[0008] One of the first section and the second section can at least partially surround the other of the first section and the second section to form a connection between the first section and the second section.

[0009] One of the first section and the second section may at least partially surround the other of the first section and the second section to provide at least one pair of opposing surfaces.

[0010] One of the first section and the second section may be at least partially inserted into the other of the first section and the second section.

[0011] One of the first section and the second section may include an insert portion, and the other of the first section and the second section may include a receiving portion. The insert portion may be inserted into the receiving portion.

[0012] At least one pair of opposing surfaces may be provided by a first section and a second section.

[0013] At least one pair of opposing surfaces may be provided by the insert portion and the receiving portion.

[0014] The first section and the second section may be connected to one another by an interference fit, a press fit, a friction fit, and / or an intermediate fit.

[0015] The first section and the second section may be connected to each other to provide two or more (e.g., 2, 3, 4, 5 or 6) pairs of opposing surfaces. For example, a first surface of the first section may face a first surface of the second section, and a second surface of the first section may face a second surface of the second section, thereby providing two pairs of opposing surfaces.

[0016] One opposing surface of each pair of opposing surfaces may be provided by the receiving portion and one opposing surface of the same pair of opposing surfaces may be provided by the insert portion.

[0017] One, multiple pairs, or each pair of opposing surfaces may independently extend substantially axially relative to the axis of the housing. One, multiple pairs, or each pair of opposing surfaces may independently extend substantially radially relative to the axis of the housing. One, multiple pairs, or each pair of opposing surfaces may independently extend substantially obliquely relative to the axis of the housing. For example, one pair of opposing surfaces may extend substantially axially relative to the axis of the housing and another pair of opposing surfaces may extend substantially radially relative to the axis of the housing.

[0018] The axis of the housing may correspond to an axis extending between ends of the housing (e.g., between an upper end and a lower end). The axis of the housing may correspond to a longitudinal axis of the housing. The axis of the housing may correspond to an axis along which the first section and the second section are connected to one another.

[0019] The opposing surfaces may have substantially the same hardness. The opposing surfaces may have a Shore A hardness of 4-80.

[0020] The opposing surfaces may be made from the same material.

[0021] The opposing surface may be made from a rigid material.

[0022] The opposing surface may be made from a hydrophobic material.

[0023] Non-limiting examples of suitable materials for use as the counter surface include plastic, glass, and metal. In some embodiments, the hydrophobic material is a plastic. Non-limiting examples of suitable materials include nylon, polypropylene, silicone, or polycarbonate.

[0024] In embodiments, the at least one surface feature may be the only means for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel.

[0025] In embodiments, the article may include a dedicated sealing element to inhibit or prevent capillary flow of the aerosolizable material from the reservoir through the capillary channel. The dedicated sealing element may be a soft sealing element such as an O-ring. The dedicated sealing element may be provided in the capillary channel. In embodiments, the article may not include a dedicated sealing element.

[0026] At least one of the opposing surfaces may include two or more surface features.

[0027] Two or more of the opposing faces may include at least one surface feature.

[0028] Two or more of the opposing faces may include two or more surface features.

[0029] The at least one surface feature may extend continuously around its respective opposing surface such that the aerosolizable material cannot flow from the reservoir through the capillary channel without being obstructed by the at least one surface feature.

[0030] The at least one surface feature may comprise at least one groove. The at least one surface feature may be at least one groove. The at least one surface feature may include a hydrophobic material, such as a hydrophobic coating.

[0031] The at least one groove has a width and a depth.

[0032] The at least one groove may have a width of at least 0.3 mm. The at least one groove may have a width of at most 2.0 mm, or at most 1.0 mm, or at most 0.8 mm, or at most 0.6 mm.

[0033] The at least one groove may have a depth of at least 0.3 mm. The at least one groove may have a depth of at most 2.0 mm, or at most 1.0 mm, or at most 0.8 mm, or at most 0.6 mm.

[0034] The at least one groove may be generally or substantially annular in configuration.

[0035] The at least one groove may be substantially straight in a side view.

[0036] At least one groove may be substantially curved in side view.

[0037] At least one of the grooves may have a wavy configuration when viewed from the side.

[0038] The at least one groove may form a tortuous path in a side view.

[0039] The at least one groove may form a zigzag in a side view.

[0040] When there is more than one groove, the grooves may be spaced apart from one another.

[0041] When there is more than one surface feature, each surface feature may independently comprise any feature described herein, including any combination of features described herein.

[0042] According to a second aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an article for use as part of the non-combustion aerosol delivery system according to the first aspect of the present disclosure and a device comprising one or more of a power source and a controller.

[0043] According to a third aspect of the present disclosure, there is provided a method of manufacturing an article according to the first aspect of the present disclosure, comprising the steps of: Providing a housing having a first section and a second section; connecting the first section and the second section to one another to form a reservoir for the aerosolizable material, the first section and the second section being connected to provide at least one pair of opposing surfaces; Including, a capillary channel is provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel; A method is provided.

[0044] 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.

[0045] 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]

[0046] [Figure 1] 1 is a schematic diagram of an aerosol delivery system according to the present disclosure. [Diagram 2]1 is a cross-sectional side view of an article for use as part of a non-combustion aerosol delivery system according to the present disclosure. [Diagram 3] FIG. 3 is an enlarged cross-sectional side view of a portion of the article of FIG. 2. [Figure 4] 3 is a perspective view of a first section of the article of FIG. 2. FIG. [Diagram 5] 3 is a side view of a second section of the article of FIG. 2. [Figure 6] FIG. 2 is a side view of an exemplary second section of an article of the present disclosure. [Figure 7] FIG. 2 is a side view of another exemplary second section of an article of the present disclosure. [Figure 8] FIG. 2 is a side view of another exemplary second section of an article of the present disclosure. [Figure 9] FIG. 2 is an enlarged cross-sectional side view of a portion of an article of the present disclosure. [Figure 10] FIG. 2 is an enlarged cross-sectional side view of an alternative article of the present disclosure. [Figure 11] FIG. 2 is an enlarged cross-sectional side view of an alternative article of the present disclosure. [Figure 12] FIG. 2 is an enlarged cross-sectional side view of an alternative article of the present disclosure. [Figure 13] FIG. 2 is an enlarged cross-sectional side view of an alternative article of the present disclosure. [Figure 14] FIG. 2 is an enlarged cross-sectional side view of an alternative article of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] 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.

[0048] As mentioned above, the present disclosure relates to non-combustion aerosol delivery systems and devices that generate aerosols from aerosol-generating materials (which may also be referred to herein as aerosolizable materials) without (but are not limited to) burning the aerosol-generating materials. Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (which generate aerosols using a combination of aerosol-generating materials). 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] In some examples, consumables / items for use with non-combustion aerosol delivery devices may include aerosol generating materials, aerosol generating material storage areas (which may also be referred to herein as reservoirs), aerosol generating material transport components, aerosol generators (which may also be referred to herein as aerosol generating components), aerosol generating areas (which may also be referred to herein as chambers), housings, wrappers, filters, mouthpieces, and / or aerosol modifiers.

[0054] 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.

[0055] The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain active substances and / or flavorings, for example. 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] As used herein, the term "component" is used to refer to a part, section, unit, module, assembly, or the like, of a non-combustion aerosol delivery system, such as an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly 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 one another, or may be permanently joined to one another during manufacture 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 one another, 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 as a device / control unit having a battery for providing power to operate the elements for generating vapor from the aerosol generating material.

[0060] 1 is a highly schematic illustration (not to scale) of an exemplary non-combustion aerosol / vapor delivery system, such as an e-cigarette 10. The e-cigarette 10 may have a generally cylindrical shape extending along a longitudinal axis, shown in dashed line, and comprises two main components: a control or power component or section 20 (which may also be referred to as a device), and a cartridge assembly or section 30 (which may also be referred to herein as an article, consumable, cartomizer, or cartridge), which operates as a vapor generating component.

[0061] The cartridge assembly 30 includes a storage compartment 3 (which may also be referred to herein as a reservoir) that contains an aerosolizable material that includes (for example) a liquid formulation from which an aerosol is generated, for example containing nicotine. By way of example, the aerosolizable material may include approximately 1-3% nicotine and 50% glycerol, with the remainder 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 include a volume 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 the aerosolizable material is disposable after it 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 devices, 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 to absorb the aerosolizable material and transfer it by wicking or capillary action to another portion of the wick that is in contact with the vapor generating element 4. This causes the aerosolizable material to be vaporized and replaced by new aerosolizable material transferred by the wick to the vapor generating element 4.

[0062] The combination of a heater and wick, or other configuration 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 FIG. 1. For example, the wick may be an entirely separate element from the aerosol generation component, or the aerosol generation component may be configured such that it is porous and capable of performing the wicking function directly (e.g., by taking the form of a suitable electrically resistive mesh or capillary body).

[0063] 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.

[0064] 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.

[0065] 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.

[0066] The power component 20 includes a cell or battery 5 (hereinafter also referred to as a battery, which may be rechargeable) for powering the electrical components of the e-cigarette 10, in particular 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 inhalation in 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.

[0067] 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. Embodiments and examples of the present invention are applicable to any of these and other configurations as will be recognized by those of skill in the art.

[0068] 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.

[0069] These structures can provide suitable sized voids and gaps between the metal fibers to provide capillary forces for the wicking phenomenon of liquids. These structures can therefore also be considered porous as they provide for liquid uptake and distribution. 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.

[0070] 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. substantially 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 substantially transverse to the surface direction, i.e. substantially perpendicular to the plane of the generally planar sheet-like aerosol-generating component. An example of such a configuration can be found in WO 2018 / 211252, the contents of which are incorporated herein by reference in their entirety.

[0071] The aerosol-generating component may have any one of the following structures: woven, mesh, fabric, open-pore fiber, open-pore sintered, open-pore foam or open-pore deposited structure. 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 may also be obtained in thin pore designs.

[0072] In one embodiment, the aerosol-generating component has at least two layers, the layers comprising at least one of the following structures: plate, foil, paper, mesh, woven structure, fabric, open-hole fiber structure, open-hole sintered structure, open-hole foam or open-hole stack structure. For example, the aerosol-generating component can be formed by an electric heating resistor consisting of a metal foil combined with a structure comprising a capillary structure. If the aerosol-generating component is considered to be formed from a single layer, such a layer may be formed from a metal wire fabric or from a non-woven metal fiber fabric. 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 fabric (materials such as AISI 304 or AISI 316). Alternatively, the aerosol-generating component can be designed as a sintered composite consisting of at least two layers of stainless steel wire fabric. The layers may be connected to each other by spot welding or resistance welding. The individual layers may also be mechanically connected to each other. For example, a double-layer wire fabric can be produced by simply folding a single layer. Instead of stainless steel, for 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 a plurality of individual fibers together. Thus, the aerosol-generating component can be composed of sintered fibers, such as sintered metal fibers.

[0073] 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".

[0074] 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 metal strands. 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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 tendency for electrical current to flow through certain areas.

[0079] 2-5 show an exemplary article (or consumable) 100 for use as part of a non-combustion aerosol delivery system 10 according to the present disclosure.

[0080] The article 100 comprises a housing 101 having a first section 102 and a second section 103. The first section 102 and the second section 103 together form a reservoir 104 for an aerosolizable material 200. The first section 102 and the second section 103 are connected to each other to provide at least one pair of opposing surfaces 106, 108 and 107, 109. A capillary channel 110 is provided between at least one of the opposing surfaces 106, 108 and 107, 109. Typically, the capillary channel 110 is an artifact of the process of manufacturing the article 100. That is, manufacturing tolerances result in the capillary channel 110 being provided between the opposing surfaces 106, 108 and 107, 109. In use, aerosolizable material 200 in reservoir 104 may leak through capillary channel 110 where it is drawn through capillary channel 110 by capillary forces. Those skilled in the art will appreciate that a capillary channel is a channel through which liquid aerosolizable material can be drawn by capillary forces at the surface of the channel.

[0081] Capillary leakage is undesirable for a number of reasons. For example, leaked aerosolizable material 200 can cause inconvenience and / or discomfort, thereby negatively impacting the user experience. Also, leaked aerosolizable material 200 is wasted. Additionally, leaked aerosolizable material 200 can affect the performance of system 10 and / or cause the user to perceive system 10 as malfunctioning.

[0082] In the article 100 of the present invention, at least one of the facing surfaces 106-109 includes at least one surface feature 111 for inhibiting or preventing capillary flow of the aerosolizable material 200 from the reservoir 104 through the capillary channel 110. The surface feature 111 impedes the capillary flow of the aerosolizable material 200 through the capillary channel 110, thereby inhibiting or preventing capillary leakage of the aerosolizable material 200 from the reservoir 104 via the capillary channel 110. The aerosolizable material 200 is partially or completely prevented from flowing from the reservoir 104 into the at least one surface feature 111.

[0083] In this particular embodiment, each surface feature 111 is a groove. The use of grooves has been found to be particularly effective in reducing or preventing leakage through the capillary channel. Without wishing to be bound by theory, it is believed that the at least one groove provides additional separation between the opposing surfaces such that capillary forces cannot be maintained, thus reducing or preventing aerosolizable material from being drawn through the channel. Additionally, it is believed that capillary forces of the opposing surfaces 106-109 retain the aerosolizable material 200 within the capillary channel 110 upstream of the at least one groove 111 (as shown in FIG. 3).

[0084] Due to the sealing effect of the at least one surface feature 111, a dedicated (e.g., separate and / or non-integral) sealing element, such as an O-ring, may not be necessary to inhibit or prevent capillary flow of the aerosolizable material 200 from the reservoir 104 through the capillary channel 110. Thus, the article 100 of the present invention may be manufactured without including such a dedicated sealing element. In fact, the at least one surface feature 111 may be the only means for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir 104 through the capillary channel 110. Thus, the article 100 of the present invention may be more cost-effective to manufacture compared to prior art articles, since the material costs of providing a dedicated sealing element may be avoided. Furthermore, the article 100 of the present invention may be easier to manufacture compared to prior art articles, since the step of assembling a dedicated sealing element within the article may be avoided. Furthermore, the article 100 of the present invention may be more reliable than prior art articles, since the risk of degradation, malfunction and / or failure of a dedicated sealing element may be avoided. These issues are particularly relevant for articles having soft seals, such as O-rings, that may be subject to manufacturing imperfections and may degrade over time, for example due to exposure to certain chemicals and / or certain environmental conditions. Furthermore, even if a dedicated sealing element such as an O-ring is not included, it is possible to form each portion of the housing from similar materials while still limiting or preventing leakage of the aerosolizable material, thereby simplifying manufacturing.

[0085] In the embodiment of FIG. 2, the housing 101 is generally cylindrical in form and has an upper end (opposite the second section 103) and a lower end (at the second section 103). The housing 101 has a longitudinal axis extending between its upper and lower ends. However, those skilled in the art will appreciate that the housing 101 and its first and second sections 102, 103 may be provided in a variety of different forms. For example, the housing 101 may be generally polygonal in form, such as a generally rectangular prism form. For example, the housing 101 may be generally plate-like in form. For example, the housing 101 may be tapered towards one or both ends.

[0086] In the embodiment of FIG. 2, the first section 102 is generally cylindrical in form. The first section 102 has a receiving portion 112 in the form of an end defining an opening to a space. The exact form of the receiving portion 112 may be varied. The first section 102 also has an opposite end that is closed. The second section 103 is generally plate-like in form. The second section 103 has an insert portion 113 that is inserted into the receiving portion 112. The second section 103 has an abutment portion 114 that extends radially from the insert portion 113. The abutment portion 114 abuts the receiving portion 112. Thus, the reservoir 104 corresponds to the space enclosed by the first section 102 and the second section 103. As mentioned above, the exact form and arrangement of the first section 102 and the second section 103 may be varied. For example, in some embodiments, the abutment portion 114 is optional.

[0087] The first section 102 and the second section 103 may be connected to provide two or more (e.g., 2, 3, 4, 5 or 6 pairs) of opposing surfaces 106, 108 and 107, 109. In the embodiment of Figure 2, the first surface 106 of the first section 102 faces the first surface 108 of the second section 103, and the second surface 107 of the first section 102 faces the second surface 109 of the second section 103, thereby providing two pairs of opposing surfaces 106, 108 and 107, 109.

[0088] One, multiple or each pair of opposing surfaces 106, 108 and 107, 109 may independently extend substantially axially, substantially radially or substantially obliquely with respect to the axis of the housing 101. The axis of the housing 101 may be an axis that extends between the ends of the housing 101 (i.e., between the upper and lower ends). The axis of the housing 101 may be the longitudinal axis of the housing 101. The axis of the housing 101 may be an axis along which the first section 102 and the second section 103 are connected to each other (as described below).

[0089] In the embodiment of Figure 2, one pair of opposing surfaces 106, 108 extend substantially axially relative to the longitudinal axis of the housing 101, and another pair of opposing surfaces 107, 109 extend substantially radially relative to the longitudinal axis of the housing. Thus, the axial opposing surfaces 106, 108 are substantially perpendicular to the radial opposing surfaces 107, 109. As mentioned above, a capillary channel 110 is provided between the opposing surfaces 106, 108 and 107, 109.

[0090] Those skilled in the art will appreciate that the capillary channel 110 is shown diagrammatically in the figures. For example, the manner in which the first section 102 and the second section 103 are connected to one another is such that portions of the opposing surfaces 106-109 contact one another while other portions of the opposing surfaces 106-109 are spaced apart to form the capillary channel 110. Because manufactured articles are not identical, due at least in part to manufacturing tolerances, the exact form of the capillary channel 110 may vary from article to article. Those skilled in the art will appreciate that the opposing surfaces 106-109 may be provided in a variety of different forms that may vary depending on the shape of the first section 102 and the second section 103.

[0091] In the embodiment of Figure 2, at least one of the facing surfaces 106-109 includes two or more surface features 111 to inhibit or prevent capillary flow of the aerosolizable material from the reservoir through the capillary channel. In some embodiments, there may be one surface feature 111 (as shown in Figures 7 and 8). In some embodiments, two or more of the facing surfaces 106-109 include at least one surface feature 111 to inhibit or prevent capillary flow of the aerosolizable material from the reservoir through the capillary channel (as shown in Figure 12).

[0092] In the illustrated embodiment, each surface feature 111 is a groove (although it will be understood that other surface features are envisioned). The grooves 111 can take a variety of different forms and configurations. In the embodiment of FIG. 2, each groove 111 is substantially straight when viewed from the side (as shown in FIG. 5). In other embodiments, at least one groove 111 may be substantially curved when viewed from the side (as shown in FIG. 6). In other embodiments, at least one groove 111 may have a wavy form when viewed from the side (as shown in FIG. 7). In other embodiments, at least one groove 111 may form a serpentine path when viewed from the side (as shown in FIG. 8). For example, at least one groove 111 may form a zigzag when viewed from the side. An advantage of substantially curved (e.g., wavy or serpentine) or zigzag grooves is that they may encompass a large surface area. By encompassing a large surface area, the risk of capillary leakage may be further reduced.

[0093] 2, each groove 111 has a substantially polygonal cross-section when taken perpendicular to the groove 111 (see, e.g., FIG. 9). In other embodiments, at least one groove 111 may have a substantially curved or U-shaped cross-section when taken perpendicular to the groove 111 (as shown in FIG. 10).

[0094] 2, the (axial) opposing surface 108 of the second section 103 includes two grooves 111. In some embodiments, at least one opposing surface 106 of the first section 102 includes at least one groove 111 (as shown in FIG. 11).

[0095] When there is more than one pair of opposing surfaces 106, 108 and 107, 109, at least one of the opposing surfaces of each pair may comprise at least one surface feature 111 (as shown in Figures 13 and 14). In Figure 13, the (axial) opposing surface 108 of the second section 103 comprises at least one surface feature 111, and the (radial) opposing surface 109 of the second section 103 comprises at least one surface feature 111. In Figure 14, the (axial) opposing surface 106 of the first section 102 comprises at least one surface feature 111, and the (radial) opposing surface 107 of the first section 102 comprises at least one surface feature 111.

[0096] In the embodiment of FIG. 2, the surface features 111 are spaced apart from one another, and each surface feature 111 is substantially annular in form. Each surface feature 111 extends continuously around its respective opposing surface 106-109 such that the aerosolizable material 200 cannot flow from the reservoir 104 through the capillary channel 110 without being blocked by at least one surface feature 111. This configuration is effective to prevent capillary leakage of the aerosolizable material from the reservoir. More specifically, each surface feature 111 extends continuously around the (axial) opposing surface 108 of the second section such that the aerosolizable material 200 cannot flow from the reservoir 104 through the capillary channel without being blocked by at least one surface feature 111.

[0097] In some embodiments, at least one surface feature 111 may extend partially around its respective opposing surface 106-109. Such embodiments may include multiple surface features 111. Multiple surface features 111 may together provide effective sealing performance.

[0098] The at least one groove 111 may have a depth of at least 0.3 mm. The at least one groove 111 may have a width of at least 0.3 mm. Such dimensions have been found to provide particularly effective sealing performance. The at least one groove 111 may have a width of up to 2.0 mm, or up to 1.0 mm, or up to 0.8 mm, or up to 0.6 mm. The at least one groove 111 may have a depth of up to 2.0 mm, or up to 1.0 mm, or up to 0.8 mm, or up to 0.6 mm.

[0099] Those skilled in the art will appreciate that the groove 111 may be provided in a variety of configurations and dimensions. For example, the groove 111 may be generally annular in configuration or may not be annular in configuration.

[0100] In an embodiment, one of the first section 102 and the second section 103 at least partially surrounds the other of the first section 102 and the second section 103 (see, for example, FIG. 2). One of the first section 102 and the second section 103 can at least partially surround the other of the first section 102 and the second section 103 to form a connection between the first section 102 and the second section 103. For example, one of the first section 102 and the second section 103 can at least partially surround the other of the first section 102 and the second section 103 to provide at least one pair of opposing surfaces 106, 108. Thus, one of the first section 102 and the second section 103 can be at least partially inserted into the other of the first section 102 and the second section 103. It will be understood that other arrangements are also envisioned.

[0101] The first section 102 and the second section 103 may be connected to one another by an engineered fit. For example, the first section 102 and the second section 103 may be connected to one another by an interference fit, a press fit, a friction fit, and / or an intermediate fit. These fits can provide a secure connection and simplify manufacturing of the article 100.

[0102] In an embodiment, one of the first and second portions 102, 103 at least partially surrounds the other of the first and second portions 102, 103 to form a connection between the first and second sections 102, 103, the connection being one or more of an interference fit, a press fit, a friction fit and / or an intermediate fit. With this arrangement, a simple and secure connection may be formed between the first and second sections 102, 103. Thus, separate fastening means (e.g., screws and pins) for connecting the first and second sections 102, 103 to each other may not be necessary, as there may be fewer required components with potential for failure.

[0103] In the embodiment of FIG. 2, the receiving portion 112 surrounds the insert portion 113 to provide an interference fit, press fit, friction fit and / or intermediate fit between the first section 102 and the second section 103. Those skilled in the art are familiar with how to provide such types of engineered fits by sizing the first section 102 and the second section 103 accordingly. In some embodiments, the opposing surfaces 106-109 may have substantially the same hardness. The opposing surfaces 106-109 may have a Shore A hardness of 4-80. In the context of the present invention, hardness is measured using the Shore A scale. Such hardness has been found to provide surface features 111 that are particularly effective at sealing against capillary leakage.

[0104] The opposing surfaces 106-109 may be made from the same material. The advantage of this is that the manufacture of the article may be simplified.

[0105] The opposing surfaces 106-109 may be made from a rigid material, which has been found to provide a robust article that is particularly effective at sealing against capillary leakage.

[0106] The facing surfaces 106-109 may be made from or treated with a hydrophobic material, which can help inhibit or prevent migration of the aerosolizable material by capillary action and thus inhibit or prevent capillary leakage through the capillary channels.

[0107] Non-limiting examples of suitable materials for use as opposing surfaces 106-109 include plastic, glass, and metal. Non-limiting examples of suitable materials include nylon, polypropylene, silicone, or polycarbonate. The first section 102 may be formed from any of the materials disclosed herein. The second section 102 may be formed from any of the materials disclosed herein.

[0108] The manufacture of the article 100 will now be described by way of non-limiting example. The first section 102 and the second section 103 of the housing 101 can be provided by any suitable technique, such as injection molding. The first section 102 and the second section 103 are connected to one another to form a reservoir 104 for the aerosolizable material 200, and the first section 102 and the second section 103 are connected to one another to provide at least one pair of opposing surfaces 106, 108 and 107, 109. Due to manufacturing tolerances of the first section 102 and the second section 103, a capillary channel 110 is provided between the opposing surfaces 106, 108 and 107, 109. At least one of the opposing surfaces 106-109 includes at least one surface feature 111 for inhibiting or preventing capillary flow of the aerosolizable material 200 from the reservoir 104 through the capillary channel 110.

[0109] To connect the first section 102 and the second section 103 to each other, the first section 102 and the second section 103 may be pressed together, which may cause at least a portion of one of the first section 102 and the second section 103 to be inserted into the other of the first section 102 and the second section 103 (depending on the configuration of the first section 102 and the second section 103, respectively). In other words, this may cause one of the first section 102 and the second section 103 to at least partially surround the other of the first section 102 and the second section 103.

[0110] 2, insert portion 113 is inserted through opening 112 such that abutment portion 114 abuts the end of first section 102 that defines opening 112. Due to the sizing of first section 102 and second section 103, respectively, said insertion provides a secure connection between first section 102 and second section 103. The connection may be by an engineered fit, such as an interference fit, press fit, friction fit and / or transition fit.

[0111] The aerosolizable material 200 may be deposited in the reservoir 104 prior to connecting the first section 102 and the second section 103 to one another. Alternatively, the aerosolizable material 200 may be deposited in the reservoir 104 after the first section 102 and the second section 103 are connected to one another, for example, by inserting the aerosolizable material 200 through an aperture (not shown) in the housing 101 which is subsequently sealed (e.g., by heat). Typically, the aerosolizable material 200 is a liquid (although a gel may also be used).

[0112] In the illustrated embodiment, the surface features 111 are grooves, although it is envisioned that other forms of surface features may be used. For example, the surface features may include a hydrophobic material (e.g., a hydrophobic coating).

[0113] The drawings presented 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 to 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 present 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. a housing having a first section and a second section that together form a reservoir for an aerosolizable material, the first section and the second section being connected to one another to provide at least one pair of opposing surfaces; a capillary channel is provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature for inhibiting or preventing capillary flow of an aerosolizable material from the reservoir through the capillary channel. An article for use as part of a non-combustion aerosol delivery system.

2. The article of claim 1 , wherein one of the first section and the second section at least partially surrounds the other of the first section and the second section.

3. The article of claim 1 or 2, wherein the first section and the second section are connected to one another by an interference fit, a press fit, a friction fit, and / or an intermediate fit.

4. The article of any one of claims 1 to 3, not including a sealing element dedicated to inhibiting or preventing capillary flow of aerosolizable material from the reservoir through the capillary channel.

5. The article of any one of claims 1 to 4, wherein at least one of the opposing surfaces comprises two or more surface features for preventing capillary flow of aerosolizable material from the reservoir through the capillary channel.

6. The article of any one of claims 1 to 5, wherein at least one surface feature extends continuously around each opposing surface of the surface features such that aerosolizable material cannot flow from the reservoir through the capillary channel without being obstructed by the at least one surface feature.

7. The article of claim 1 , wherein the at least one surface feature is at least one groove.

8. 8. The article of claim 7, wherein the at least one groove has a width of at least 0.3 mm.

9. 9. The article of claim 7 or 8, wherein the at least one groove has a depth of at least 0.3 mm.

10. The article of any one of claims 7 to 9, wherein at least one groove is generally or substantially annular in configuration.

11. The article of any one of claims 7 to 10, wherein at least one groove is substantially straight in a side view.

12. The article of any one of claims 7 to 11, wherein at least one groove is substantially curved in side view.

13. The article according to any one of claims 7 to 12, wherein at least one groove has a wavy form when viewed from the side.

14. The article of any one of claims 7 to 13, wherein at least one groove forms a tortuous path in a side view.

15. The article of any one of claims 7 to 14, wherein the at least one groove forms a zigzag in a side view.

16. The article of any one of claims 1 to 15, wherein the opposing surfaces have substantially the same hardness.

17. The article of any one of claims 1 to 16, wherein the opposing surface has a Shore A hardness of 4 to 80.

18. The article of any one of claims 1 to 17, wherein the aerosolizable material is an aerosolizable liquid.

19. 1. A non-combustion aerosol delivery system comprising: An article according to any one of claims 1 to 18 for use as part of said non-combustion aerosol delivery system; A device comprising one or more of a power supply and a controller; A non-combustion aerosol delivery system comprising:

20. A method for producing an article according to any one of claims 1 to 18, comprising the steps of: Providing a housing having a first section and a second section; connecting the first section and the second section to one another to form a reservoir for an aerosolizable material, the first section and the second section being connected to one another to provide at least one pair of opposing surfaces; Including, a capillary channel is provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature for inhibiting or preventing capillary flow of an aerosolizable material from the reservoir through the capillary channel. method.

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