Delivery System

Abstract

The present invention relates to an aerosol generating component that includes a material having grains, the orientation of the grains of the material being substantially perpendicular to an axis along which the electrical connector of the aerosol generating component is disposed.

Description

[Technical field]

[0001] The present invention relates to delivery systems, particularly non-combustion aerosol delivery systems and components of said aerosol delivery systems. The present invention further relates to methods of generating and delivering aerosols using the non-combustion aerosol delivery systems and components disclosed herein. [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 of these properties. Summary of the Invention

[0006] According to a first aspect of the present disclosure, there is provided an aerosol generating component comprising a material having grains, the orientation of the grains of the material being substantially perpendicular to an axis along which an electrical connector of the aerosol generating component is disposed. The axis along which the electrical connector of the aerosol generating component is disposed may correspond to a first axis.

[0007] In some instances, the material has a crystalline structure.

[0008] In some examples, the orientation of the grains of the material is substantially perpendicular to the axis about which the aerosol generating component is curved, which may correspond to the second axis.

[0009] In some examples, the aerosol generation component includes a heating section.

[0010] In some examples, one or more elongated apertures (eg, slot-like apertures) are provided in the aerosol generation component, for example the heating section.

[0011] In some examples, the heating section is provided between the electrical connectors.

[0012] In some examples, the aerosol generation component (e.g., heating section) comprises a plurality of elongated heating portions. The heating portions may be arranged side-by-side. The heating portions may extend between respective terminal portions. In some examples, an elongated aperture (e.g., a slot-like aperture) is provided between adjacent heating portions.

[0013] The aerosol generating component may be formed from an electrically conductive material.

[0014] The aerosol-generating component may be formed by a single layer.

[0015] The aerosol-generating component may be substantially planar.

[0016] According to one aspect of the present disclosure, an aerosol generating component is provided that includes a material having grains, wherein the orientation of the grains of the material is approximately parallel to one or more elongated apertures (e.g., slot-like apertures) within the aerosol generating component.

[0017] In some instances, the orientation of the grains of the material is approximately perpendicular to the axis about which the aerosol generating component is curved.

[0018] In some examples, the heating section is provided between electrical connectors of the aerosol generation components.

[0019] In some examples, the heating section comprises a plurality of elongated heating portions. The heating portions may be arranged side-by-side. The heating portions may extend between respective terminal portions. In some examples, an elongated aperture (e.g., a slot-like aperture) is provided between adjacent heating portions. The aerosol generation component may be formed from an electrically conductive material.

[0020] The aerosol-generating component may be formed by a single layer.

[0021] The aerosol-generating component may be substantially planar.

[0022] According to one aspect of the present disclosure, there is provided an article 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 a reservoir for an aerosolizable material and an aerosol generating chamber.

[0023] In some examples, the aerosol generation component is disposed at least partially within the aerosol generation chamber.

[0024] In some examples, the reservoir is configured to supply aerosolizable material to the aerosol generation component.

[0025] In some examples, the reservoir is configured to hold a liquid aerosolizable material.

[0026] According to one aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an article comprising an aerosol generating component according to the previous aspect of the present disclosure and a device comprising one or more of a power source and a controller.

[0027] In some examples, the power source is configured to provide power to the aerosol generation component via the electrical connector.

[0028] According to one aspect of the present disclosure, a method of manufacturing an aerosol generating component is provided, the method comprising the steps of providing an aerosol generating component comprising a material having grains, and processing the material such that the orientation of the grains of the material is approximately perpendicular to an axis along which an electrical connector of the aerosol generating component is located.

[0029] According to one aspect of the present disclosure, a method of manufacturing an aerosol generating component is provided, the method including the steps of providing an aerosol generating component including a material having grains, and processing the material such that the orientation of the grains of the material is approximately parallel to one or more elongated (e.g., slot-like) apertures provided in the aerosol generating component.

[0030] 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.

[0031] 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]

[0032] [Figure 1] 1 is a schematic diagram of an aerosol delivery system according to the present disclosure. [Diagram 2] FIG. 1 is a diagram of an article for use as part of an aerosol delivery system according to the present disclosure. [Diagram 3] FIG. 3 is an exploded view of the article of FIG. 2. [Figure 4] 3 is a rough sketch of an aerosol-generating component for use in the article of FIG. 2 according to the present disclosure. [Diagram 5] FIG. 3 is a schematic diagram of an aerosol-generating component for use in the article of FIG. 2 according to the present disclosure. [Figure 6] FIG. 3 is a schematic diagram of an aerosol-generating component for use in the article of FIG. 2 according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] [Detailed Description] 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.

[0034] 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.

[0035] Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may be used, with it being understood that these terms may be used interchangeably with any non-combustion aerosol (vapor) delivery system or device as described above.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] In some examples, consumables / items for use with non-combustion aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage regions (which may also be referred to herein as a reservoir of aerosolizable material), aerosol-generating material transport components (e.g., wicks such as pads), aerosol generators (which may also be referred to herein as an aerosol-generating component), aerosol-generating regions (which may also be referred to herein as an aerosol-generating chamber), housings, wrappers, filters, mouthpieces, and / or aerosol modifiers.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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, 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) capable of holding 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.

[0046] 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 may have 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 also be referred to herein 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.

[0047] 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 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 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 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 causes the aerosolizable material to be vaporized and replaced by new aerosolizable material transferred by the wick to the aerosol generating component 4.

[0048] 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).

[0049] 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.

[0050] 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 components, the aerosol generating components collect and condense the generated vapor to form the required aerosol.

[0051] 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.

[0052] The power component 20 includes a cell or battery 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] 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.

[0058] 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 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 cloth 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.

[0059] 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".

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] FIG. 2 is a diagram of an exemplary article 100 according to the present disclosure. The article 100 comprises a housing. In this particular example, the housing comprises an outer housing 110 and an inner housing 120. The outer housing 110 is formed by the integration of first and second outer housing components 110a and 110b. The specific appearance of the outer housing 110 is not limited, but in this particular example, the outer housing 110 has a multi-faceted surface. The housing, e.g., the outer housing 110, can include at least one outlet 115. In this particular example, there are two outlets 115. The outlets 115 are for conveying the aerosol generated within the article 100 to the mouth of the user. Thus, in the example shown in FIG. 2, the outer housing 110 also forms the mouthpiece of the article.

[0066] The first outer housing component 110a mates with the second outer housing component 110b to form the outer housing 110. In this particular example, the components 110a, 110b mate with one another via a snap-fit ​​arrangement. In particular, a resilient tab 111 (only one side of which is visible in FIG. 2) of the second outer housing component 110b snaps into a corresponding receiving aperture 112 of the first outer housing component 110a. It will be appreciated that the exact location of the tab and aperture is not limited, and in fact the tab may be formed in the outer housing component 110a and the aperture may be formed in the outer housing component 110b.

[0067] 3, the first outer housing component 110a is shown separated from the second outer housing component 110b to reveal the inner housing component 120, the aerosol generating component 130 (an electrically resistive metal heater in this particular example), the flow regulator 140, and the pad 150. The inner housing component 120 may be configured to define a storage area 121 for the aerosolizable material (not shown). The inner housing component 120 may be at least partially sleeved inside the first outer housing component 110a. It is possible to connect the inner housing component 120 to the first outer housing component 110a (e.g., they may be attached to each other or may be part of the same molding). The inner housing component 120 may have an open end 122 that mates with the flow regulator 140. The open end 122 and the flow regulator 140 together may define a path for the aerosolizable material to flow from the storage area 121 to the pad 150. An optional mouthpiece (not shown) may be sleeved over the outside of first outer housing component 110a (or the outer housing may form the mouthpiece).

[0068] The flow regulator 140 may include a recess 141 that may receive the open end 122 of the inner housing component 120. The recess 141 may include one or more openings 142 that allow for the flow of aerosolizable material through the flow regulator. In this particular example, the openings are slot-shaped, but it will be appreciated that one or more of the openings may have a different cross-section, such as circular, elliptical, or polygonal. Additionally, the cross-sectional area of ​​the opening or openings may vary through the length of the flow regulator. Thus, the opening or openings may have a larger cross-sectional area toward the liquid storage area compared to the cross-sectional area toward the pad 150. The flow regulator 140 may include an annular seal 143 around its periphery that functions to inhibit the escape of aerosolizable material from the interface between the inner housing component 120 and the flow regulator 140. The flow regulator 140 may include a surface against which the aerosol generating component may be biased, thus potentially functioning as a heater support.

[0069] The pad 150 may be formed of a capillary material suitable for holding the aerosolizable material. In particular, as the aerosolizable material flows through the flow regulator 140, the pad 150 may become saturated with the aerosolizable material. However, the capillary nature of the pad 150 inhibits leakage of the aerosolizable material from the pad 150. The aerosol generating component 130 may be positioned in close proximity to the pad 150 such that when the aerosol generating component 130 is energized (resistively heated in this particular example), the aerosolizable material present within the pad 150 is vaporized. As discussed above, the pad 150 and the aerosol generating component 130 may be combined into a single component.

[0070] In this particular example, the aerosol generation component 130 is disposed toward the second outer housing component 110b. Electrical contacts (e.g., pins) 116 on the outer housing component 110b may contact the aerosol generation component 130 at electrical connectors (e.g., tabs) 130C to allow electrical current to flow through the aerosol generation component 130 during operation of the system.

[0071] The second outer housing component 110b can include at least one air inlet 117 that allows for the entry of air into the article 100. During use, air can enter the article 100 via the at least one air inlet 117, thereby mixing with vapor generated from the aerosol generating component 130. The resulting aerosol can then be directed to one or more air outlets 115 via at least one air flow channel 180 that extends between the first outer housing component 110a and the inner housing component 120. For example, in this particular example, there are two air flow channels 180 that extend longitudinally along the length of the article 100 and cooperate with the air outlets 115 to form a flow path through the article.

[0072] According to one aspect, an aerosol generating component is provided that includes a material having grains, the orientation of the grains of the material being generally perpendicular to an axis along which the electrical connector of the aerosol generating component is located. By providing the grains of the material in this direction, the aerosol generating component can be made to be more resistant to breaking or cracking of the material when the aerosol generating component is forced into a curved shape, for example by bending the aerosol generating component against the grain orientation. The aerosol generating component can also be made to be more resistant to permanent deformation that may occur when the aerosol generating component is forced into a curved shape, for example by bending the aerosol generating component against the grain orientation. It will be understood that "grain orientation" refers to the orientation in which regions of the material are aligned. Materials such as metals can be engineered to include a particular grain orientation.

[0073] This embodiment is most clearly shown in the sketch of Figure 4, where the orientation of the grains of the material is designated by dashed lines. An exemplary aerosol generating component 130 that may have a grain orientation of this embodiment is shown in Figures 5 and 6 (although the grain orientation is not shown in Figures 5 and 6).

[0074] The axis along which the electrical connector of the aerosol generation component is arranged may correspond to the first axis.

[0075] The material may have a crystalline structure. It will be appreciated that any suitable material may be used, as known to those skilled in the art. For example, the material may be an electrically conductive material. For example, the material may be a metallic material, such as a metal, or a metal alloy, such as stainless steel. Other materials, such as Nichrome and NiCrFe alloys, are also contemplated.

[0076] The orientation of the grains of the material may be substantially perpendicular to the axis about which the aerosol generating component 130 is curved (e.g., in use). Advantageously, this may help to ensure that the curved form of the aerosol generating component 130 is maintained. In this regard, the aerosol generating component 130 may include a permanent curvature, or may be curved when assembled into an article in use (e.g., due to connectivity to and shapes of its surrounding components). The axis about which the aerosol generating component is curved may correspond to the second axis.

[0077] The aerosol-generating component 130 may be substantially planar. The aerosol-generating component 130 may be formed from a single layer.

[0078] Each of the electrical connectors 130C may be configured to connect to a respective electrical contact. The electrical connectors 130C may be arranged on an axis.

[0079] It will be appreciated that the form and dimensions of the electrical connector 130C may be varied. For example, the or each electrical connector 130C may be configured to connect to the respective electrical contacts 116. In this manner, the aerosol generation component 130 may be powered by a power source, such as a battery. The or each electrical connector 130C may be configured to releasably or permanently connect to the respective electrical contacts 116. The or each electrical connector 130C may be configured to connect to the respective electrical contacts by a clearance fit, an interference fit, and / or an intermediate fit. The or each electrical connector 130C may be configured to connect to the respective electrical contacts 116 by a push fit. The electrical connector 130C provides a means by which the aerosol generation component 130 may be electrically connected to a power source.

[0080] The aerosol generating component 130 may include a heating section 130A and one or more of an electrical connector 130C. In various examples, the aerosol generating component includes a heating section 130A and two electrical connectors 130A, with each electrical connector 130C provided at a respective opposite end of the heating section 130A. The heating section 130A can be considered as a portion of the aerosol generating component 130 that is heated in use to vaporize the aerosolizable material to generate an aerosol. The heating section 130A can be provided between the electrical connectors 130C. One or more elongated apertures 130B, also referred to herein as one or more longitudinal gaps 130B, may be provided in the aerosol generating component 130, for example, in the heating section 130A. The one or more elongated apertures 130B can facilitate providing "hot spots," typically around the ends, that can rapidly vaporize the aerosol generating material. The aerosol generation component 130, for example the heating section 130A, may comprise a plurality of elongated heating portions 130E, which may be arranged side-by-side. The heating portions 130E may extend between respective terminal portions 130F. An elongated gap 130B may be provided between adjacent heating portions 130E.

[0081] The aerosol-generating component 130 can be manufactured using a variety of different techniques, as will be familiar to those skilled in the art, for example, a variety of different material processing techniques can be used to orient the grains of the material as desired.

[0082] According to an alternative embodiment, there is provided an aerosol generating component comprising a material having grains, the orientation of the grains of the material being generally parallel to one or more elongated apertures in the aerosol generating component. By providing the grains of the material in this direction, the aerosol generating component can be made to be more resistant to breaking or cracking of the material when the aerosol generating component is forced into a curved shape, for example by bending the aerosol generating component against the grain orientation. The aerosol generating component can also be made to be more resistant to possible permanent deformation when the aerosol generating component is forced into a curved shape, for example by bending the aerosol generating component against the grain orientation.

[0083] This embodiment is most clearly shown in the sketch of Figure 4, where the orientation of the grains of the material is designated by dashed lines. An exemplary aerosol generating component 130 that may have a grain orientation of this embodiment is shown in Figures 5 and 6 (although the grain orientation is not shown in Figures 5 and 6).

[0084] The aerosol-generation component 130, including the elongated aperture 130B and any other features thereof, may be as defined elsewhere herein.

[0085] The aerosol-generating component 130 can be manufactured using a variety of different techniques, as will be familiar to those skilled in the art, for example, a variety of different material processing techniques can be used to orient the grains of the material as desired.

[0086] Also provided is an article 100 for use as part of a non-combustion aerosol delivery system comprising an aerosol generating component 130 as defined herein and one or more of a reservoir for an aerosolizable material and an aerosol generating chamber.

[0087] In some examples, the aerosol generation component 103 is disposed at least partially within the aerosol generation chamber.

[0088] In some examples, the reservoir is configured to supply aerosolizable material to the aerosol generating component 103.

[0089] In some examples, the reservoir is configured to hold a liquid aerosolizable material.

[0090] There is also provided a non-combustion aerosol delivery system comprising an article comprising an aerosol generating component 103 as defined herein and a device comprising one or more of a power source and a controller.

[0091] In some examples, the power source is configured to provide power to the aerosol generation component 103 via the electrical connector 130C.

[0092] According to one aspect, an aerosol generating component is provided that includes a plurality of elongated heating portions extending between terminal portions, with elongated apertures between adjacent heating portions, at least one of the elongated apertures being tapered in the longitudinal direction. Without being bound by theory, it is believed that the tapered portion of the longitudinal aperture introduces a temperature gradient in the heating portion as a result of the central portion of each aperture being located away from an adjacent edge of the heating portion at the wider end of each aperture compared to the narrower end, which helps to drive the aerosolizable material along the heating portion and distribute the aerosolizable material across the heating portion. This results in more effective heating of the aerosolizable material, reducing the amount of aerosolizable material that is "static" on the aerosol generating component and reducing "crackling" sounds that may occur when said static aerosolizable material is heated.

[0093] This embodiment is most clearly shown in Figure 5, where the aerosol generating component 130 comprises a plurality of elongated heating portions 130E (for clarity, not all of the heating portions 130E are numbered) extending between terminal portions 130E. Elongated apertures 130B (also referred to herein as slotted apertures) are provided between adjacent heating portions 130E. At least one of the elongated apertures 130B tapers in the longitudinal direction (i.e., along the length of the aperture 130B). In use, aerosolizable material is dispensed along the elongated aperture 130B in the direction of increasing taper. In this example, the heating portions 130E are arranged side-by-side.

[0094] A plurality of longitudinally tapered elongated apertures 130B may be provided in the aerosol generation component 130. Each elongated aperture 130B may be provided between each pair of adjacent heating portions 130E. At least two adjacent elongated apertures 130B may taper in opposite directions. For example, when there are a plurality of elongated apertures 130B, the elongated apertures 130B may alternately taper in opposite directions. This may help to provide a more uniform distribution of the aerosolizable material across the heating portions 130E, thus improving aerosol generation.

[0095] At least one elongated heating portion 130E may have a substantially constant cross-sectional area, and the cross-section may be perpendicular to the length of the heating portion 130E.

[0096] At least one of the elongated apertures 130B may be surrounded. This is particularly suitable for effecting transfer of the aerosolizable material through the surrounded elongated aperture structure (e.g., by capillary forces between adjacent heating portions 130E surrounding the elongated aperture 130B) to provide a uniform distribution of the aerosolizable material across the heating portion 130E, particularly in "hot spots" that may be located at the ends of the elongated aperture 130B. In some examples, at least one elongated aperture 130B is surrounded within or by the periphery of the aerosol generation component 130. For example, at least one elongated aperture 130 may be surrounded by adjacent heating portions 130E and opposing terminal portions 130F.

[0097] For example, at least one (or each) of the elongated apertures 130B may have a maximum width of at most 2.0 mm, or at most 1.8 mm, or at most 1.6 mm, or at most 1.5 mm, or at most 1.4 mm, or at most 1.2 mm, or at most 1.0 mm. For example, at least one (or each) of the elongated apertures 130B may have a minimum width of at least 0.1 mm, or at least 0.2 mm, or at least 0.3 mm, or at least 0.4 mm. This may also help to facilitate movement of the aerosolizable material along opposing edges of the heated portion 130E, for example by capillary forces.

[0098] In some examples, the aerosol generating component 130 is formed from a single layer.

[0099] In some examples, the aerosol generating component 130 is formed from an electrically conductive material.

[0100] The aerosol-generating component 130 may include any other features defined elsewhere herein.

[0101] Also provided is an article for use as part of a non-combustion aerosol delivery system that includes an aerosol generating component 130 and one or more of a reservoir for aerosolizable material and an aerosol formation chamber.

[0102] A non-combustion aerosol delivery system is also provided that includes an article that includes an aerosol generating component 130 and a device that includes one or more of a power source and a controller.

[0103] According to an alternative aspect, an aerosol generating component is provided that includes a plurality of elongated heating portions extending between terminal portions, with an elongated aperture between adjacent heating portions, at least one of the heating portions being tapered in the longitudinal direction. In use, the most tapered (i.e., thinnest) portion of the heating portion is heated to the operating temperature first (because it has the highest electrical resistance), followed by the less tapered portions of the heating portion (because they have relatively lower electrical resistance). This non-uniformity of heating along the heating portion results in a temperature gradient that can help drive the aerosolizable material along the heating portion and distribute the aerosolizable material across the heating portion. This results in more effective heating of the aerosolizable material, reducing the amount of aerosolizable material that is "static" on the aerosol generating component and reducing "crackling" sounds that can occur when said static aerosolizable material is heated.

[0104] This embodiment is most clearly shown in Figure 6, where the aerosol generation component 130 comprises a plurality of elongated heating portions 130E (not all of which are numbered for clarity) extending between terminal portions 130F. Elongated apertures 130B (also referred to herein as slot-like apertures 130B) are provided between adjacent heating portions 130E. At least one of the heating portions 130E is tapered in the longitudinal direction (i.e. along the length of the heating portion 130E). In this example, the heating portions 130E are arranged side-by-side.

[0105] In some examples, the plurality of elongated heating segments 130E may be tapered in the longitudinal direction.

[0106] A plurality of elongated apertures 130B may be provided in the aerosol generation component, each of which may be provided between a respective pair of adjacent heating portions 130E.

[0107] The at least one elongated heating aperture 130B may have a substantially constant width (see FIG. 6).

[0108] At least two adjacent heating portions 130E may taper in opposite directions. For example, if there are multiple heating portions 130E, the heating portions 130E may alternately taper in opposite directions. This may help to provide a more uniform distribution of the aerosolizable material across the heating portions 130E.

[0109] At least one of the elongated apertures 130B may be surrounded. In some examples, at least one elongated aperture 130B is surrounded within or by the periphery of the aerosol generation component 130. For example, at least one elongated aperture 130B may be surrounded by an adjacent heating portion 130E and an opposing terminal portion 130F.

[0110] For example, at least one (or each) of the heating portions 130E may have a maximum width of at most 2.0 mm, or at most 1.8 mm, or at most 1.6 mm, or at most 1.5 mm, or at most 1.4 mm, or at most 1.2 mm, or at most 1.0 mm. For example, at least one (or each) of the heating portions 130E may have a minimum width of at least 0.1 mm, or at least 0.2 mm, or at least 0.3 mm, or at least 0.4 mm. This may further help to facilitate movement of the aerosolizable material along the heating portion.

[0111] The aerosol-generating component 130 may include any other features defined elsewhere herein.

[0112] Also provided is an article for use as part of a non-combustion aerosol delivery system comprising an aerosol generating component 130 as defined herein and one or more of a reservoir for aerosolizable material and an aerosol generating chamber.

[0113] In some examples, the aerosol generation component 103 is disposed at least partially within the aerosol generation chamber.

[0114] In some examples, the reservoir is configured to supply aerosolizable material to the aerosol generating component 103.

[0115] In some examples, the reservoir is configured to hold a liquid aerosolizable material.

[0116] There is also provided a non-combustion aerosol delivery system comprising an article comprising an aerosol generating component 103 as defined herein and a device comprising one or more of a power source and a controller.

[0117] In some examples, the power source is configured to provide power to the aerosol generation component 103 via the electrical connector 130C.

[0118] The 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. Furthermore, the present disclosure can include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An aerosol generating component comprising a material having grains, the orientation of the grains of the material being approximately perpendicular to an axis along which an electrical connector of the aerosol generating component is disposed.

2. The aerosol generating component of claim 1 , wherein the material has a crystalline structure.

3. 3. The aerosol generating component of claim 1, wherein the orientation of the grains of the material is substantially perpendicular to an axis about which the aerosol generating component is curved.

4. An aerosol generating component according to any one of claims 1 to 3, comprising a heating section.

5. The aerosol generating component of claim 4 , wherein the heating section is disposed between the electrical connectors.

6. An aerosol generating component according to any one of claims 1 to 5, wherein one or more elongated apertures are provided in the aerosol generating component.

7. 7. An aerosol generating component according to any preceding claim, comprising a plurality of elongated heating portions arranged side-by-side.

8. 8. An aerosol generating component according to claim 5 or 7, wherein an elongated aperture is provided between adjacent heating portions.

9. 9. An aerosol generating component according to any preceding claim which is substantially planar.

10. 10. An aerosol-generating component according to any preceding claim, which is formed by a single layer.

11. An aerosol generating component according to any preceding claim formed from an electrically conductive material.

12. An aerosol generating component comprising a material having grains, the orientation of the grains of the material being generally parallel to one or more elongated apertures provided in the aerosol generating component.

13. 13. The aerosol generating component of claim 12, wherein the orientation of the grains of the material is substantially perpendicular to an axis about which the aerosol generating component is curved.

14. 14. An aerosol generating component according to claim 12 or 13, comprising a heating section.

15. 15. The aerosol generating component of claim 14, wherein the heating section is provided between electrical connectors of the aerosol generating component.

16. 16. An aerosol generating component according to any one of claims 12 to 15, comprising a plurality of elongated heating portions arranged side-by-side.

17. The aerosol generating component of claim 16 , wherein an elongated aperture is provided between adjacent heating portions.

18. 18. An aerosol generating component according to any one of claims 12 to 17 which is substantially planar.

19. An aerosol-generating component according to any one of claims 12 to 18, which is formed by a single layer.

20. 20. An aerosol generating component according to any one of claims 12 to 19, formed from an electrically conductive material.

21. An article for use as part of a non-combustion aerosol delivery system comprising an aerosol generating component according to any one of claims 1 to 20 and one or more of a reservoir for aerosolizable material and an aerosol generating chamber.

22. The article of claim 21 , wherein the aerosol generating component is at least partially disposed within the aerosol generating chamber.

23. 23. The article of claim 21 or 22, wherein the reservoir is configured to supply aerosolizable material to the aerosol generating component.

24. The article of any one of claims 21 to 23, wherein the reservoir is configured to hold a liquid aerosolizable material.

25. A non-combustion aerosol delivery system comprising an article comprising an aerosol generating component according to any one of claims 1 to 20, and a device comprising one or more of a power source and a controller.

26. 26. The non-combustion aerosol delivery system of claim 25, wherein the power source is configured to provide power to the aerosol generation component via the electrical connector.

27. 1. A method of producing an aerosol generating component, comprising the steps of: Providing an aerosol generating component that includes a material having grains; processing the material such that the orientation of the grains of the material is substantially perpendicular to an axis along which an electrical connector of the aerosol generation component is disposed; A method comprising:

28. 1. A method of producing an aerosol generating component, comprising the steps of: Providing an aerosol generating component that includes a material having grains; processing the material such that the orientation of the grains of the material is substantially parallel to one or more elongated apertures in the aerosol generation component; A method comprising:

Images