Aerosol Delivery Systems

Abstract

The present invention relates to an article for use as part of a non-combustion aerosol delivery system, comprising a housing having at least one air inlet and a generally planar aerosol generating component contained within the housing, the at least one air inlet being configured to direct air towards the aerosol generating component in an inlet airflow direction, and the plane of the generally planar aerosol generating component being inclined obliquely relative to the inlet airflow direction.

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 one aspect of the present disclosure, there is provided an article for use as part of a non-combustion aerosol delivery system, comprising: a housing having at least one air inlet; a generally planar aerosol generating component contained within a housing; Equipped with at least one air inlet is configured to direct air towards the aerosol generation component in an inlet airflow direction, the plane of the generally planar aerosol generation component being inclined obliquely with respect to the inlet airflow direction; The item is provided.

[0007] In some examples, the plane of the generally planar aerosol generation element is inclined at about 140° to about 160° relative to the inlet airflow direction.

[0008] In some examples, the plane of the generally planar aerosol generation element is inclined at about 130° to about 150° relative to the inlet airflow direction.

[0009] In some examples, the plane of the aerosol generation component is inclined obliquely in one or more directions relative to the inlet airflow direction.

[0010] In some examples, the plane of the aerosol generation component is inclined obliquely in only one direction relative to the inlet airflow direction.

[0011] In some examples, the housing comprises an aerosol formation chamber.

[0012] In some examples, the aerosol generation components are disposed at least partially within the aerosol formation chamber.

[0013] In some examples, the housing defines a single airflow channel.

[0014] In some examples, a single air flow channel extends between the at least one air inlet and the at least one air outlet.

[0015] In some examples, the aerosol generation component includes one or more elongated apertures.

[0016] In some examples, the aerosol generating component is formed from an electrically conductive material.

[0017] In some examples, the aerosol-generating material is formed from a porous material.

[0018] In some examples, the aerosol generating component is formed from a single layer.

[0019] In some examples, the aerosol generation component includes one or more electrical connectors.

[0020] In some examples, the article comprises a reservoir for an aerosolizable material.

[0021] In some examples, the article comprises an aerosol-generating material transfer component configured to transfer the aerosolizable material from the reservoir to the aerosol-generating component (eg, by capillary forces).

[0022] According to one aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0023] According to one aspect of the present disclosure, there is provided an article for use as part of a non-combustion aerosol delivery system, the article comprising an aerosol generating component and an aerosol-generating material transport component configured to transport an aerosol-generating material to the aerosol generating component, wherein the aerosol generating component and the aerosol-generating material transport component are magnetically connected to one another.

[0024] In some examples, one of the aerosol-generating component and the aerosol-generating material transport component includes a magnetic material, and the other of the aerosol-generating component and the aerosol-generating material transport component includes a corresponding magnetic material.

[0025] In some examples, one or both of the magnetic material and the corresponding magnetic material are permanent magnets.

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

[0027] In some examples, the aerosol generation component is substantially planar.

[0028] In some examples, the aerosol generation component is curved.

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

[0030] In some examples, the aerosol-generating material transport component is curved about the axis of the aerosol-generating component.

[0031] In some examples, the article comprises an aerosol-forming chamber.

[0032] In some examples, the aerosol generation components are disposed at least partially within the aerosol formation chamber.

[0033] In some examples, the aerosol generation component includes one or more elongated apertures.

[0034] In some examples, the aerosol generation component comprises a plurality of elongated heating portions, which may be arranged side-by-side.

[0035] In some examples, an elongated aperture is provided between adjacent elongated heating portions.

[0036] In some examples, the aerosol generating component is formed from an electrically conductive material.

[0037] In some examples, the aerosol-generating material is formed from a porous material.

[0038] In some examples, the aerosol generating component is formed from a single layer.

[0039] In some examples, the aerosol generating component and the aerosol generating material transport component are non-permanently connected to one another.

[0040] In some examples, the aerosol generating component and the aerosol generating material transport component are releasably connected to one another.

[0041] In some examples, the article comprises a reservoir for an aerosolizable material.

[0042] In some examples, the aerosol generating material transfer component is configured to transfer the aerosolizable material from the reservoir to the aerosol generating component.

[0043] According to one aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0044] According to one aspect of the present disclosure, an aerosol generation component is provided that includes at least two generally planar portions, at least two of the generally planar heating portions being in different planes from one another.

[0045] In some examples, at least two of the generally planar portions that lie in different planes define an oblique interior angle.

[0046] In some examples, the interior angle is between about 30° and about 60°.

[0047] In some examples, the interior angle is between about 40° and about 50°.

[0048] In some examples, at least two of the generally planar portions in different planes are connected end-to-end to one another.

[0049] In some examples, the aerosol generation component (eg, one or each of the at least two generally planar portions) includes one or more elongated apertures.

[0050] In some examples, the aerosol generation component (e.g., one or each of the at least two generally planar portions) comprises a plurality of elongated heating portions. The plurality of elongated heating portions may be arranged side-by-side.

[0051] In some examples, an elongated aperture is provided between adjacent elongated heating portions.

[0052] In some examples, the aerosol generation component is configured such that the air flow moves perpendicular to a boundary between at least two generally planar portions that are in different planes.

[0053] In some examples, the aerosol generating component is formed from an electrically conductive material.

[0054] In some examples, the aerosol generating component is formed from a porous material.

[0055] In some examples, the aerosol generating component is formed from a single layer.

[0056] According to one aspect of the present disclosure, there is provided an article for use as part of a non-combustion aerosol delivery system, the article comprising an aerosol generating component according to the previous aspect and one or more of a reservoir for an aerosolizable material and an aerosol formation chamber.

[0057] In some examples, the aerosol generation component is disposed at least partially within the aerosol formation chamber.

[0058] In some examples, the article comprises at least one air inlet to the aerosol formation chamber.

[0059] In some examples, the aerosol-generating component is positioned to direct air entering the article via the at least one air inlet to at least two of the generally planar portions that are in different planes.

[0060] In some examples, at least two of the generally planar portions in different planes are positioned to direct air entering the article via the at least one air inlet in different directions.

[0061] In some examples, the oblique interior angle is on a side of the aerosol generation component distal from the at least one air inlet.

[0062] In some examples, the article is configured such that air flow (eg, entering via at least one air inlet) moves perpendicular to a boundary between at least two generally planar portions that are in different planes.

[0063] According to one aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0064] According to one aspect of the present disclosure, an article is provided for use as part of a non-combustion aerosol delivery system, the article comprising a housing, an aerosol generating component, and an aerosol-generating material transport component, wherein the aerosol generating component and the aerosol-generating material transport component are contained within the housing, and the aerosol generating component is biased against the aerosol-generating material transport component.

[0065] In some instances, the aerosol generating component is securely attached to the housing or a component therein.

[0066] In some examples, the aerosol generation component includes one or more electrical connectors securely attached to one or more corresponding electrical contacts in the housing.

[0067] In some instances, the aerosol-generating material transport components are spatially constrained by the housing or components therein.

[0068] In some examples, the aerosol generation component is substantially planar.

[0069] In some examples, the aerosol generation component is curved.

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

[0071] In some examples, the aerosol-generating material transport component is curved about the axis of the aerosol-generating component.

[0072] In some examples, the axis of the aerosol generating component is one or more of a longitudinal axis of the aerosol generating component and an axis extending between electrical contacts of the aerosol generating component.

[0073] In some examples, the article comprises an aerosol-forming chamber.

[0074] In some examples, the aerosol generation components are disposed at least partially within the aerosol formation chamber.

[0075] In some examples, the aerosol generation component includes one or more elongated apertures.

[0076] In some examples, the aerosol generation component comprises a plurality of elongated heating portions, which may be arranged side-by-side.

[0077] In some examples, an elongated aperture is provided between adjacent elongated heating portions.

[0078] In some examples, the aerosol generating component is formed from an electrically conductive material.

[0079] In some examples, the aerosol-generating material is formed from a porous material.

[0080] In some examples, the aerosol generating component is formed from a single layer.

[0081] In some examples, the housing defines at least one airflow channel.

[0082] According to one aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an article according to the previous aspect and a device comprising one or more of a power source and a controller.

[0083] The system can be configured such that the airflow channel and / or the aerosol generation chamber and / or the aerosol generation components are separable. For example, the article may be provided in a modular form in which the airflow channel and / or the aerosol generation chamber and / or the aerosol generation components are separable.

[0084] According to another aspect of the present disclosure, there is provided:

[0085] A1. An article for use as part of a non-combustion aerosol delivery system, comprising: an aerosol generating component; and an aerosol-generating material transport component configured to transport an aerosol-generating material to the aerosol generating component, wherein the aerosol generating component and the aerosol-generating material transport component are magnetically connected to one another.

[0086] A2. The article of clause A1, wherein one of the aerosol-generating component and the aerosol-generating material transport component comprises a magnetic material, and the other of the aerosol-generating component and the aerosol-generating material transport component comprises a corresponding magnetic material.

[0087] A3. The article of clause A2, wherein one or both of the magnetic material and the corresponding magnetic material are permanent magnets.

[0088] A4. The article of clause A2 or A3, wherein one or both of the magnetic material and the corresponding magnetic material are temporary magnets or electromagnets.

[0089] A5. The article of any one of clauses A1-A4, wherein the aerosol-generating component is substantially planar.

[0090] A6. The article of any one of clauses A1-A5, wherein the aerosol generation component is curved.

[0091] A7. The article of clause A6, wherein the aerosol-generating component is curved about the axis of the aerosol-generating component.

[0092] A8. The article of clause A7, wherein the aerosol-generating material transport component is curved about the axis of the aerosol-generating component.

[0093] A9. The article of any one of clauses A1-A8, comprising an aerosol-forming chamber.

[0094] A10. The article of any one of clauses A1-A9, wherein the aerosol generation component is disposed at least partially within the aerosol formation chamber.

[0095] A11. The article of any one of clauses A1-A10, wherein the aerosol-generating component includes one or more elongated apertures.

[0096] A12. The article of any one of clauses A1-A11, wherein the aerosol-generating component is formed from an electrically conductive material.

[0097] A13. The article of any one of clauses A1-A12, wherein the aerosol-generating component is formed from a porous material.

[0098] A14. The article of any one of clauses A1-A13, wherein the aerosol-generating component is formed from a single layer.

[0099] A15. The article of any one of clauses A1-A14, wherein the aerosol-generating component and the aerosol-generating material transport component are non-permanently connected to one another.

[0100] A16. The article of any one of clauses A1-A15, wherein the aerosol-generating component and the aerosol-generating material transfer component are releasably connected to one another.

[0101] A17. The article of any one of clauses A1-A16, comprising a reservoir for an aerosolizable material, the aerosol generating material transfer component configured to transfer the aerosolizable material from the reservoir to the aerosol generating component.

[0102] A18. A non-combustion aerosol delivery system comprising an article according to any one of clauses A1-A17 and a device comprising one or more of a power source and a controller.

[0103] According to another aspect of the present disclosure, there is provided:

[0104] B1. An aerosol-generating component comprising at least two generally planar portions, at least two of the generally planar portions being in different planes from one another.

[0105] B2. The aerosol-generating component of clause B1, wherein at least two of the generally planar portions in different planes define an oblique interior angle.

[0106] B3. The aerosol-generating component of clause B2, wherein the internal angle can be from about 30° to about 60°.

[0107] B4. The aerosol-generating component of clause B3, wherein the included angle can be from about 40° to about 50°.

[0108] B5. The aerosol generation component of any one of clauses B1-B4, wherein at least two of the generally planar portions that lie in different planes are connected end-to-end to one another.

[0109] B6. An aerosol generating component according to any one of clauses B1-B5, comprising one or more elongated apertures.

[0110] B7. The aerosol generating component of clause B6, comprising a plurality of elongated heating portions.

[0111] B8. The aerosol generating component of clause B7, wherein an elongated aperture is provided between adjacent elongated heating portions.

[0112] B9. The aerosol generating component of any one of clauses B1-B8, configured so that the air flow moves perpendicular to a boundary between at least two generally planar portions that are in different planes.

[0113] B10. The aerosol generating component of any one of clauses B1-B9 formed from a conductive material.

[0114] B11. The aerosol-generating component of any one of clauses B1-B10 formed from a porous material.

[0115] B12. An aerosol-generating component according to any one of clauses B1-B11 formed from a single layer.

[0116] B13. An article for use as part of a non-combustion aerosol delivery system, comprising an aerosol generating component according to any one of clauses B1-B12 and one or more of a reservoir for an aerosolizable material and an aerosol formation chamber.

[0117] B14. The article of clause B13, wherein the aerosol-generating component is disposed at least partially within the aerosol-formation chamber.

[0118] B15. The article of clause B13 or B14, comprising at least one air inlet to the aerosol formation chamber.

[0119] B16. The article of clause B15, wherein the aerosol-generating component is positioned to direct air entering the article through the at least one air inlet into at least two of the generally planar portions that are in different planes.

[0120] B17. The article of clause B15 or B16, wherein at least two of the generally planar portions in different planes are positioned to direct air entering the article through the at least one air inlet in different directions.

[0121] B18. The article of any one of clauses B15-B17, wherein the aerosol-generation component is characterized according to clause B2, and the oblique internal angle is on a side of the aerosol-generation component distal from the at least one air inlet.

[0122] B19. The article of any one of clauses B13-B18, configured so that the air flow moves perpendicular to a boundary between at least two generally planar portions that are in different planes.

[0123] B20. A non-combustion aerosol delivery system comprising an article according to any one of clauses B13-B19 and a device comprising one or more of a power source and a controller.

[0124] According to another aspect of the present disclosure, there is provided:

[0125] C1. An article for use as part of a non-combustion aerosol delivery system, comprising: a housing; an aerosol generating component; and an aerosol-generating material transport component, wherein the aerosol generating component and the aerosol-generating material transport component are contained within the housing, and the aerosol generating component is biased against the aerosol-generating material transport component.

[0126] C2. The article of clause C1, wherein the aerosol-generating component is securely attached to the housing or a component therein.

[0127] C3. The article of clause C1 or C2, wherein the aerosol generating component comprises one or more electrical connectors securely attached to one or more corresponding electrical contacts in the housing.

[0128] C4. The article of any one of clauses C1-C3, wherein the aerosol-generating material transport component is spatially constrained by the housing or a component therein.

[0129] C5. The article of any one of clauses C1-C3, wherein the aerosol-generating material transport component is not securely attached to the housing or a component therein.

[0130] C6. The article of any one of clauses C1-C5, wherein the aerosol-generating component is substantially planar.

[0131] C7. The article of any one of clauses C1-C6, wherein the aerosol-generating component is curved.

[0132] C8. The article of clause C7, wherein the aerosol-generating component is curved about the axis of the aerosol-generating component.

[0133] C9. The article of clause C7 or C8, wherein the aerosol-generating material transport component is curved about the axis of the aerosol-generating component.

[0134] C10. The article of any one of clauses C1-C9, comprising an aerosol-forming chamber.

[0135] C11. The article of clause C10, wherein the aerosol generating component is disposed at least partially within the aerosol formation chamber.

[0136] C12. The article of any one of clauses C1-C11, wherein the aerosol-generating component includes one or more elongated apertures.

[0137] C13. The article of any one of clauses C1-C12, wherein the aerosol-generating component is formed from an electrically conductive material.

[0138] C14. The article of any one of clauses C1-C13, wherein the aerosol-generating component is formed from a porous material.

[0139] C15. The article of any one of clauses C1-C14, wherein the aerosol-generating component is formed from a single layer.

[0140] C16. The article of any one of clauses C1-C15, wherein the housing defines at least one air flow channel.

[0141] C17. A non-combustion aerosol delivery system comprising an article according to any one of clauses C1-C16 and a device comprising one or more of a power source and a controller.

[0142] It will be appreciated that features of the invention described above with respect to any aspect of the invention are equally applicable to, and may be combined with, embodiments of the invention according to any other aspect of the invention, as appropriate, and not just in the specific combinations described above.

[0143] 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]

[0144] [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 4A] FIG. 1 is a schematic diagram of an exemplary aerosol generating component according to the present disclosure. [Figure 4B] FIG. 1 is a schematic diagram of an exemplary aerosol generating component according to the present disclosure. [Figure 4C] FIG. 1 is a schematic diagram of an exemplary aerosol generating component according to the present disclosure. [Diagram 5] 5A and 5B are schematic diagrams of exemplary aerosol generating components according to the present disclosure. [Figure 5C] FIG. 1 is a schematic diagram of an exemplary aerosol generating component according to the present disclosure. [Figure 5D] FIG. 1 is a schematic diagram of an exemplary aerosol generating component according to the present disclosure. [Figure 6] 1 is a schematic diagram of an exemplary article for use as part of an aerosol delivery system according to the present disclosure (although various portions of the article have been omitted for clarity); DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0145] 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.

[0146] As mentioned above, the present disclosure relates to non-combustion aerosol delivery systems and devices that generate aerosols from aerosol-generating materials (or 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 (using a combination of aerosol-generating materials to generate aerosols). In some examples, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating materials is not a requirement of the present disclosure. In some examples, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system. In some examples, the non-combustion aerosol delivery system is a hybrid system that generates aerosols using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials of such a hybrid system may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some examples, hybrid systems include a liquid or gel aerosol-forming material and a solid aerosol-forming material, which may include, for example, tobacco or non-tobacco products.

[0147] 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.

[0148] 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.

[0149] A non-combustion aerosol delivery system typically includes a device portion (i.e., a device) and a consumable / article portion (i.e., 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.

[0150] 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.

[0151] In some examples, consumables / items for use with non-combustion aerosol delivery devices may include aerosol-generating material (i.e., aerosolizable material), an aerosol-generating material storage region (i.e., a reservoir for aerosolizable material), an aerosol-generating material transport component (e.g., a wick such as a pad), an aerosol generator (i.e., an aerosol-generating component), an aerosol-generating region (i.e., an aerosol-generating chamber), a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0152] 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.

[0153] 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.

[0154] 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.

[0155] 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.

[0156] 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.

[0157] As used herein, the term "component" is used to refer to a part, section, unit, module, assembly, or the like of an electronic cigarette or similar device that incorporates several smaller parts or elements that may be within an external housing or wall. An electronic cigarette may be formed or constructed from one or more such components, which may be removably or separably connectable to each other, or may be permanently joined to each other during manufacturing to define the entire electronic cigarette. The present disclosure is applicable (without being limited thereto) to a system comprising two components that are separably connectable to each other, the two components being configured, for example, as a consumable / article component (also referred to herein as a cartridge or cartomizer) that can hold an aerosol generating material, and a device / control unit having a battery for providing power to operate the elements for generating vapor from the aerosol generating material.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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.

[0163] 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.

[0164] 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.

[0165] 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.

[0166] 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.

[0167] 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.

[0168] 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.

[0169] 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.

[0170] 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.

[0171] 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.

[0172] 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.

[0173] 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).

[0174] 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.

[0175] 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.

[0176] 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.

[0177] 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.

[0178] 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.

[0179] 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.

[0180] 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.

[0181] 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.

[0182] 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.

[0183] 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.

[0184] 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".

[0185] 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.

[0186] 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.

[0187] 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.

[0188] 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.

[0189] 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.

[0190] 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.

[0191] 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.

[0192] With reference to FIG. 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 (which may be an electrically resistive metal heater), 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. Thus, the inner housing component 120 may be at least partially surrounded by 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 can define a path for 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 the first outer housing component 110a (or the outer housing may form the mouthpiece).

[0193] 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 understood that one or more of the openings may have a different cross-section, such as circular, elliptical, or polygonal. Furthermore, the cross-sectional area of ​​the one or more openings 142 may vary through the length of the flow regulator 140. Thus, the one or more openings 142 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 130 may be biased, thus potentially functioning as a heater support.

[0194] 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 (resistive heating 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.

[0195] 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.

[0196] 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 extending 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 100.

[0197] According to one aspect, an article for use as part of a non-combustion aerosol delivery system includes a housing having at least one air inlet, a generally planar aerosol generating component contained within the housing, wherein at least one air inlet is configured to direct air toward the aerosol-generating component in an inlet airflow direction, and a plane of the generally planar aerosol-generating component is inclined obliquely with respect to the inlet airflow direction.

[0198] It will be understood that the "inlet airflow direction" refers to the direction in which air is directed through at least one air inlet towards the aerosol generating component. By providing such an angle between the inlet airflow direction and the plane of the generally planar aerosol generating component, the generally planar aerosol generating component can direct air from the at least one air inlet in a particular direction through the article. In this way, an article with a single airflow channel can be manufactured, and air from the at least one air inlet can be effectively directed towards the airflow channel. This configuration can also help to reduce turbulence in the airflow in the at least one airflow channel compared to when the inlet airflow direction is generally perpendicular to the plane of the generally planar aerosol generating component. By reducing the turbulence in the at least one airflow channel, the quality of the generated aerosol can be improved.

[0199] In this embodiment, the article 100 may be as described above, except that the orientation of the aerosol-generating components is different. For example, in the example of Figure 2, it will be seen that the plane of the generally planar aerosol-generating component 130 is generally perpendicular to the inlet airflow direction. In contrast, in this embodiment, the plane of the generally planar aerosol-generating component 130 is inclined obliquely to the inlet airflow direction AF, as shown generally in Figures 4A-4C.

[0200] With reference to Figure 4A, in this particular example, the plane of the generally planar aerosol-generating component 130 is inclined at about 130° to about 140° (e.g., about 135°) relative to the inlet airflow direction AF. It is envisaged that different angles may be used. For example, in the particular example of Figure 4B, the plane of the generally planar aerosol-generating component 130 is inclined at about 140° to about 160° (e.g., about 150°) relative to the inlet airflow direction AF. In Figures 4A-4C, the inclination angle is indicated as θ.

[0201] In some examples, the plane of the generally planar aerosol generation component 130 is inclined by about 100° to about 170°, or about 110° to about 160°, or about 120° to about 150°, or about 130° to about 140° (e.g., about 135°) relative to the inlet airflow direction AF.

[0202] In some examples, the plane of the aerosol generating component 130 is inclined obliquely in one or more directions relative to the inlet airflow direction AF. Thus, the article can more effectively direct the airflow for a particular configuration. In some examples, the plane of the aerosol generating component 130 is inclined obliquely in only one direction relative to the inlet airflow direction AF. In this regard, in the examples of Figures 4A and 4B, the plane of the aerosol generating component 130 is inclined obliquely in only one direction relative to the inlet airflow direction AF, i.e., along the length of the aerosol generating component 130. In the example of Figure 4C, the plane of the aerosol generating component 130 is inclined obliquely in at least two directions, including along the length of the aerosol generating component 130 and along the width of the aerosol generating component 130 (the latter shown in Figure 4C).

[0203] The inclination angle of the plane of the generally planar aerosol generation component 130 relative to the inlet airflow direction AF can be from about 100° to about 170°, or from about 110° to about 160°, or from about 120° to about 150°, or from about 130° to about 140° (e.g., about 135°) in one direction or in each individual direction.

[0204] In some examples, the housings 110 , 120 may include an aerosol formation chamber 190 .

[0205] The aerosol generation component 130 may be disposed at least partially within the aerosol formation chamber 190 .

[0206] The housings 110, 120 may define a single airflow channel 180 (the housing defining the single airflow channel is not shown in the figures, but would be understood by one of ordinary skill in the art). In some examples, the single airflow channel 180 may extend between at least one air inlet 117 and at least one air outlet 115.

[0207] In some examples, the aerosol generation component 130 may include one or more elongated apertures 130B (e.g., as shown in FIG. 3). The aerosol generation component 130 may include multiple elongated heating portions. The multiple elongated heating portions may be arranged side-by-side. The elongated apertures 130B may be provided between adjacent elongated heating portions.

[0208] In some examples, the aerosol generating component 130 may be formed from a conductive material. In some examples, the aerosol generating component 130 may be formed from a porous material. In some examples, the aerosol generating component 130 may be formed from a single layer.

[0209] The aerosol generation component 130 may include one or more electrical connectors 130C. Multiple elongated heating portions may be provided between the electrical connectors 130C.

[0210] Article 100 may include any other features defined herein.

[0211] Also disclosed is a non-combustion aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 that includes one or more of a power source and a controller.

[0212] System 10 may include any other features defined herein.

[0213] According to one aspect, an article for use as part of a non-combustion aerosol delivery system is disclosed, the article comprising an aerosol generating component and an aerosol-generating material transport component configured to transport an aerosol-generating material to the aerosol generating component, wherein the aerosol generating component and the aerosol-generating material transport component are magnetically connected to one another.

[0214] The magnetic connection can improve contact between the aerosol-generating components and the aerosol-generating material transport components, resulting in improved aerosolization. Additionally, the magnetic connection can simplify manufacturing of the article, since the magnetic properties of the components can help automatically align the components in a desired orientation.

[0215] The magnetic connection can be achieved in a variety of different ways. For example, the aerosol generating component 130 and the aerosol-generating material transfer component 150 may include, consist substantially of, consist essentially of, consist of, be coated with, and / or be formed of a magnetic material. Suitable magnetic materials are known to those of skill in the art.

[0216] In some examples, one of the aerosol generating component 130 and the aerosol-generating material transfer component 150 includes a magnetic material, and the other of the aerosol generating component 130 and the aerosol-generating material transfer component 150 includes a corresponding magnetic material. For example, one or both of the magnetic material and the corresponding magnetic material may be a permanent magnet. For example, one or both of the magnetic material and the corresponding magnetic material may be a temporary magnet or an electromagnet.

[0217] For example, the aerosol generating component 130 and the aerosol-generating material transfer component 150 may be non-permanently connected to one another. For example, the aerosol generating component and the aerosol-generating material transfer component may be releasably connected to one another. This may further simplify the process of manufacturing the article as compared to when a manufacturing step is required to permanently connect the aerosol generating component and the aerosol-generating material transfer component.

[0218] Furthermore, this allows the article to be at least partially disassembled and reassembled (eg, by a suitable technician) without permanently damaging the article.

[0219] The article 100 may be as defined elsewhere herein, including any features thereof. For example, the aerosol generating component 130 may be substantially planar. The aerosol generating component 130 may be curved. The aerosol generating component 130 may be curved about the axis of the aerosol generating component 130. The aerosol generating material transfer component 150 may be curved about the axis of the aerosol generating component 130. The axis of the aerosol generating component 130 may correspond to a longitudinal axis of the aerosol generating component 130. The axis of the aerosol generating component 130 may correspond to a lateral (or transverse) axis of the aerosol generating component 130. The axis of the aerosol generating component 130 may correspond to an axis extending between the electrical connectors 130C of the aerosol generating component.

[0220] The article 100 may include an aerosol formation chamber 130. The aerosol generation components may be at least partially disposed within the aerosol formation chamber 190.

[0221] In some examples, the aerosol generating component 130 may include one or more elongated apertures 130B (e.g., as shown in FIG. 3). The aerosol generating component 130 may include multiple elongated heating portions. Multiple elongated heating portions may be arranged side-by-side. An elongated aperture 130B may be provided between adjacent elongated heating portions. The aerosol generating component 130 may include one or more electrical connectors 130C. The elongated heating portions may be provided between the electrical connectors 130C. In some examples, the aerosol generating component 130 is formed from an electrically conductive material. In some examples, the aerosol generating material 130 is formed from a porous material. In some examples, the aerosol generating component 130 is formed from a single layer.

[0222] Article 100 may include any other features defined herein.

[0223] Also disclosed is a non-combustion aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 that includes one or more of a power source and a controller.

[0224] System 10 may include any other features defined herein.

[0225] According to one embodiment, an aerosol generation component is disclosed that includes at least two generally planar portions, at least two of the generally planar portions being in different planes from one another.

[0226] With this arrangement, the generally planar portions in different planes can help to guide the airflow in an article comprising the aerosol-generating component in an optimized manner. For example, different planes of the generally planar portions can guide the airflow in the article in different directions. Thus, with this arrangement, the aerosol-generating component can be tailored to the particular design configuration of the article to more effectively direct the airflow and / or reduce or limit turbulence in the airflow.

[0227] Features of this embodiment are illustrated diagrammatically in Figures 5A-5D. As shown, the aerosol-generating component 130 includes at least two generally planar portions 130A'. At least two of the generally planar portions 130A' lie in different planes from one another.

[0228] In the example of Figures 5A-5C, the aerosol-generating component 130 includes two generally planar portions 130A'. In the example of Figure 5D, the aerosol-generating component 130 includes four generally planar portions 130A'. It will be understood that other numbers of heating portions 130A' may be used.

[0229] In some examples, at least two of the generally planar portions 130A in different planes define an oblique interior angle α, which can be between about 10° and about 80°, or between about 20° and about 70°, or between about 30° and about 60°, or between about 35° and about 55°, or between about 40° and about 50°, or about 45°.

[0230] In some examples, at least two of the generally planar portions 130A' in different planes have their ends connected end-to-end to each other. This arrangement is illustrated in Figures 5A-5C. In some examples, the aerosol generation component 130 is configured such that the airflow moves perpendicular to a boundary between the at least two generally planar portions 130A' in different planes. As illustrated, the boundary corresponds to a straight line connecting the portions 130A'.

[0231] In some examples, at least two substantially planar portions 130A' in different planes each define a first direction, the respective first directions being parallel to each other, and the first directions being the only parallel directions defined by the planar heating portions 130A'. For example, with reference to FIGS. 5A-5C, two substantially planar portions 130A' in different planes each define a first direction (along the width of the portions 130A') and the first directions are parallel to each other. Other directions along each portion 130A' are not parallel to each other. It will be appreciated that various configurations are possible.

[0232] In some examples, the aerosol generation component 130 (e.g., one or each of the at least two generally planar portions 130A') may include one or more elongated apertures. For example, the aerosol generation component 130 (e.g., one or each of the at least two generally planar portions 130A') may include multiple elongated heating portions, which may be arranged side-by-side. An elongated aperture may be provided between adjacent elongated heating portions.

[0233] In some examples, the aerosol generating component 130 is formed from a conductive material. In some examples, the aerosol generating component 130 is formed from a porous material. In some examples, the aerosol generating component 130 is formed from a single layer.

[0234] The aerosol generation component 130 may include one or more electrical connectors 130C. The elongated heating portion may be provided between the electrical connectors 130C.

[0235] Also disclosed 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 121 for aerosolizable material and an aerosol formation chamber 190.

[0236] The aerosol generation component 130 may be at least partially disposed within the aerosol formation chamber 190. The article 100, e.g., the housing 110, 120, may include at least one air inlet 117 to the aerosol formation chamber 190.

[0237] The aerosol-generating component 130 may be arranged to direct air entering the article 100 via the at least one air inlet 117 to at least two of the generally planar portions 130A' that are in different planes.

[0238] At least two of the generally planar portions 130A' in different planes may be positioned to direct air entering the article 100 via the at least one air inlet 117 in different directions.

[0239] In examples where at least two of the generally planar portions 130A' in different planes define an oblique interior angle, the oblique interior angle may be on a side of the aerosol generation component 130 distal from the at least one air inlet 117. Such an arrangement may help to direct the airflow in different intended directions while reducing or limiting turbulence.

[0240] In some examples, the article 100 is configured such that the air flow travels perpendicular to a boundary between at least two generally planar portions 130A' that are in different planes. As shown in the figure, the boundary corresponds to a straight line connecting the portions 130A'.

[0241] Article 100 may include any other features defined herein.

[0242] Also disclosed is a non-combustion aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 that includes one or more of a power source and a controller.

[0243] System 10 may include any other features defined herein.

[0244] According to one aspect, an article is disclosed for use as part of a non-combustion aerosol delivery system, the article comprising an aerosol generating component and an aerosol-generating material transport component, the aerosol generating component and the aerosol-generating material transport component being contained within a housing, and the aerosol generating component being biased against the aerosol-generating material transport component.

[0245] Features of this embodiment are represented diagrammatically in Figure 6. The aerosol generating component 130 and the aerosol-generating material transfer component 150 are housed within housings 110, 120 (not shown in Figure 6). The aerosol generating component 130 is biased against the aerosol-generating material transfer component 150. In this configuration, contact between the aerosol generating component 130 and the aerosol-generating material transfer component is improved. For example, this configuration may facilitate improved delivery of aerosolizable material from the aerosol-generating material transfer component to the aerosol generating component, thus resulting in improved aerosolization.

[0246] The biasing of the aerosol generating component 130 against the aerosol generating material transfer component 150 can be accomplished in a variety of ways. For example, the aerosol generating component 130 may be rigidly attached to the housing 110, 120 or a component therein (e.g., electrical contacts 116). For example, the aerosol generating material transfer component 150 may be spatially constrained by the housing 110, 120 or a component therein (e.g., flow regulator 140). The housing and / or one or more components therein may bias each of the aerosol generating component 130 and the aerosol generating material transfer component 150. This may compress the aerosol generating component 130 and the aerosol generating material transfer component 150 together.

[0247] For example, in one example, the aerosol generating component 130 is securely attached to the electrical contacts 116, which hold the aerosol generating component 130 in place within the housings 110, 120, and the aerosol generating material transfer component 150 is spatially constrained by the flow regulator 140. Additionally, the housing 100 and each component therein are dimensioned such that, when the article 100 is assembled, the aerosol generating component 130 biases the aerosol generating material transfer component 150, e.g., compressing the components 130, 150 together.

[0248] Referring to FIG. 6, the opposing arrows in FIG. 6 indicate compressive forces exerted on the aerosol generating component 130 and the aerosol-generating material transfer component 150 (for clarity, other features of the article 100 are not shown). In some embodiments, the aerosol generating component is pre-biased in a particular orientation. Such pre-biasing may enable the aerosol generating component to maintain a particular degree of contact with the aerosol generating material. In particular, if the aerosol generating component is displaced from its pre-biased state while in contact with the aerosol generating material transfer component, the aerosol generating component may attempt to return to its pre-biased state, thus enhancing contact with the aerosol generating material transfer component. In some examples, the aerosol generating component 130 is generally planar. In some examples, the aerosol generating component 130 is curved. In some examples, the aerosol generating component 130 is curved about the axis of the aerosol generating component 130. In some examples, the aerosol generating material transfer component 150 is curved about the axis of the aerosol generating component 130. The axis of the aerosol generation component 130 may correspond to the axis between the electrical connectors 130C of the aerosol generation component 130. The axis of the aerosol generation component 130 may correspond to the longitudinal axis or the transverse (or lateral) axis of the aerosol generation component 130.

[0249] In some examples, the housings 110, 120 may comprise an aerosol-forming chamber 190. The aerosol generation component 130 may be at least partially disposed within the aerosol-forming chamber 190.

[0250] In some examples, the aerosol generating component 130 may include one or more elongated apertures 130B (e.g., as shown in FIG. 3). The aerosol generating component 130 may include multiple elongated heating portions. Multiple elongated heating portions may be arranged side-by-side. An elongated aperture may be provided between adjacent elongated heating portions. The aerosol generating component 130 may include one or more electrical connectors 130C. The elongated heating portions may be provided between the electrical connectors 130C. In some examples, the aerosol generating component 130 is formed from an electrically conductive material. In some examples, the aerosol generating material 130 is formed from a porous material. In some examples, the aerosol generating component 130 is formed from a single layer.

[0251] The article 100 may include at least one air flow channel 180 .

[0252] Article 100 may include any other features defined herein.

[0253] Also disclosed is a non-combustion aerosol delivery system 10 comprising an article 100 as defined herein and a device 20 that includes one or more of a power source and a controller.

[0254] System 10 may include any other features defined herein.

[0255] 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. 1. An article for use as part of a non-combustion aerosol delivery system, comprising: a housing having at least one air inlet; a generally planar aerosol generating component contained within the housing; Equipped with the at least one air inlet is configured to direct air towards the aerosol generation component in an inlet airflow direction, and the plane of the generally planar aerosol generation component is inclined obliquely to the inlet airflow direction; Goods.

2. 2. The article of claim 1, wherein the planar surface of the generally planar aerosol generating component is inclined at an angle of about 140° to about 160° relative to the inlet airflow direction.

3. The article of claim 2 , wherein the planar surface of the generally planar aerosol generating component is inclined at an angle of about 130° to about 150° relative to the inlet airflow direction.

4. The article of any one of claims 1 to 3, wherein the planar surface of the aerosol-generating component is inclined obliquely to the inlet airflow direction in one or two dimensions of the aerosol-generating component.

5. The article of any one of claims 1 to 4, wherein the aerosol-generating component is inclined obliquely to the inlet airflow direction in only one dimension of the aerosol-generating component.

6. The article of any one of claims 1 to 5, wherein the housing comprises an aerosol formation chamber.

7. The article of claim 4 , wherein the aerosol generating component is at least partially disposed within the aerosol formation chamber.

8. The article of any one of claims 1 to 5, wherein the housing defines a single airflow channel.

9. The article of claim 6 , wherein the single air flow channel extends between the at least one air inlet and the at least one air outlet.

10. The article of any one of claims 1 to 7, wherein the aerosol-generating component comprises one or more elongated apertures.

11. The article of any one of claims 1 to 10, wherein the aerosol-generating component is formed from an electrically conductive material.

12. The article of any one of claims 1 to 11, wherein the aerosol-generating component is formed from a porous material.

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

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

15. The article of any one of claims 1 to 14, comprising a reservoir for an aerosolizable material.

16. The article of claim 15 , comprising an aerosol-generating material transfer component configured to transfer aerosolizable material from the reservoir to the aerosol generating component.

17. A non-combustion aerosol delivery system comprising the article of any one of claims 1 to 16 and a device comprising one or more of a power source and a controller.

Images