Aerosol Delivery System

Abstract

The present invention relates to an aerosol generation component comprising at least one curved elongated aperture.

Description

Field

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

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

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

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

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

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

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

[0008] In some instances, the aerosol generating component is substantially planar.

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

[0010] In some examples, one, more, or all of the elongated slits include a plurality of elongated slit portions.

[0011] In some examples, one, more, or all of the elongated slits are substantially straight.

[0012] In some instances, one, more, or all of the elongated slits are curved, hi some instances, the curvature is in the plane of the substantially planar aerosol generation component.

[0013] In some examples, at least two of the elongated slit portions are not parallel to one another.

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

[0015] In some instances, one, more, or all of the elongated slits are open at the periphery of the aerosol generation component.

[0016] In some instances, one, more, or all of the elongated slits are surrounded by the periphery of the aerosol generation component.

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

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

[0019] In some examples, one, more, or all of the elongated slits are located in the aerosolization portion.

[0020] In some instances, one, more, or all of the elongated slits do not extend into the aerosolizable material supply portion, in other words, one, more, or all of the elongated slits may be confined to the aerosolization portion.

[0021] In some examples, one, more, or all of the elongated slits are connected to the elongated slots.

[0022] In some instances, one, more, or all of the elongated slots are located in the aerosolization portion.

[0023] In some instances, one, more, or all of the elongated slots do not extend into the aerosolizable material supply.

[0024] In some instances, one, more, or all of the elongated slits are located in the aerosolizable material supply.

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

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

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

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

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

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

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

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

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

[0034] In some examples, one, more, or all of the curved elongate openings have an increasing curvature from one end of the opening to the other end of the opening.

[0035] In some examples, one, more, or all of the curved elongate openings are curved along at least a portion of their length. The curved portion of the opening may be toward the periphery of the aerosol generating component. This may help to reduce the occurrence of hot spots during use in locations where "hot spots" are undesirable. The curved portion of the opening may be located in the aerosolizable material supply.

[0036] In some instances, one, more, or all of the curved elongate openings are curved along substantially their entire length.

[0037] In some instances, the aerosol generating component is substantially planar.

[0038] In some instances, the curvature of one, more, or all of the curved elongated apertures lies in the plane of the substantially planar aerosol generation component.

[0039] In some examples, one, more, or all of the curved elongate openings comprise a curved portion connected to a straight portion.

[0040] In some examples, one, more, or all of the curved elongate openings include a slot portion connected to a slit portion.

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

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

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

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

[0045] In some instances, one, more, or all of the curved elongated openings are open at the periphery of the aerosol generation component.

[0046] In some instances, one, more, or all of the curved elongated openings are surrounded by the periphery of the aerosol generation component.

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

[0048] In some examples, one, more, or all of the curved elongated openings include a slot portion connected to a slit portion, and one, more, or all of the slot portions are disposed in the aerosolization portion.

[0049] In some examples, one, more, or all of the curved elongated openings include a slot portion connected to a slit portion, and one, more, or all of the slit portions are provided in the aerosolizable material supply portion.

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

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

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

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

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

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

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

[0057] In one aspect of the present disclosure, an article is provided for use in a non-flammable aerosol delivery system, the article comprising: a housing; and a substantially planar aerosol generating component having at least one elongated slot and at least partially contained within the housing, the housing defining a capillary gap through which aerosolizable material can be delivered to the aerosol generating component, wherein the capillary gap and one, more than one, or all of the elongated slots do not overlap.

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

[0059] In some examples, one, more, or all of the elongated slots are disposed within the capillary gap.

[0060] In some examples, one, more, or all of the elongated slots are connected to an elongated slit to provide at least one elongated opening.

[0061] In some instances, one, more, or all of the elongated slits and capillary gaps overlap.

[0062] In some examples, the width of one, more, or all of the elongated slits is greater than 0 mm. In some examples, the width of one, more, or all of the elongated slits is at most 0.3 mm or at most 0.25 mm. In some examples, the width of one, more, or all of the elongated slits is at least 0.05 mm, at least 0.1 mm, or at least 0.15 mm. In some examples, the width of one, more, or all of the elongated slits is between 0.05 mm and 0.3 mm, between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25 mm. In some examples, the width of one, more, or all of the elongated slits is about 0.2 mm.

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

[0064] In some instances, the aerosol generating component is substantially planar.

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

[0066] In some instances, one, more, or all of the slots are located in the aerosolization portion.

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

[0068] In some examples, the aerosolization portion is disposed within the capillary gap.

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

[0070] In some examples, one, more, or all of the elongated slots are connected to elongated slits to provide at least one elongated opening, and one, more, or all of the slits are provided in the aerosolizable material supply.

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

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

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

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

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

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

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

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

[0079] The system can be configured such that the airflow channel(s), the aerosol generation chamber(s), and / or the aerosol generation component(s) are separable. For example, the article can be provided in a modular format such that the airflow channel(s), the aerosol generation chamber(s), and / or the aerosol generation component(s) are separable.

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

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

[0082] A2. The aerosol generation component of clause A1, wherein one, more or all of the curved elongate openings have an increasing curvature from one end of the opening to the other end of the opening.

[0083] A3. The aerosol generation component of clause A1 or A2, wherein one, more or all of the curved elongate openings are curved along at least a portion of their length.

[0084] A4. An aerosol generation component according to any one of clauses A1 to A3, wherein one, more or all of the curved elongate openings are curved along substantially their entire length.

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

[0086] A6. An aerosol generation component described in any one of clauses A1 to A5, wherein one, more or all of the curved elongated openings comprise a curved portion connected to a straight portion.

[0087] A7. An aerosol generation component described in any one of clauses A1 to A6, wherein one, more than one or all of the curved elongated openings comprise a slot portion connected to a slit portion.

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

[0089] A9. An aerosol generation component described in any one of clauses A1 to A8, wherein one, several or all of the curved elongated openings are open at the periphery of the aerosol generation component.

[0090] A10. An aerosol generation component according to any one of clauses A1 to A9, wherein one, several or all of the curved elongated openings are surrounded by the periphery of the aerosol generation component.

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

[0092] A12. An aerosol generating component as described in clause A11, wherein one, more or all of the curved elongated openings comprise a slot portion connected to a slit portion, and one, more or all of the slot portions are provided in the aerosolization portion.

[0093] A13. An aerosol generating component according to clause A11 or A12, wherein one, more or all of the curved elongated openings comprise a slot portion connected to a slit portion, and one, more or all of the slit portions are provided in the aerosolizable material supply portion.

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

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

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

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

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

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

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

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

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

[0103] B2. The article of clause B1, wherein one, more, or all of the elongated slots are located within the capillary gap.

[0104] B3. The article of clause B1 or B2, wherein one, more, or all of the elongated slots are connected to elongated slits to provide at least one elongated opening.

[0105] B4. The article of any one of clauses B1-B3, wherein one, more, or all of the elongated slits and capillary gaps are overlapping.

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

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

[0108] B7. An article as described in clause B6, wherein one, more or all of the elongated slots are provided in the aerosolization portion.

[0109] B8. The article of clause B6 or B7, wherein the aerosolization portion and the capillary gap do not overlap.

[0110] B9. The article of any one of clauses B6-B8, wherein the aerosolization portion is disposed within the capillary gap.

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

[0112] B11. The article of any one of clauses B6-B10, wherein one, more, or all of the elongated slots are connected to elongated slits to provide at least one elongated opening, and one, more, or all of the slits are disposed in an aerosolizable material supply.

[0113] B12. The article of any one of clauses B6-B11, wherein the housing comprises a first carrier component and a second carrier component spaced apart to define a capillary gap.

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

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

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

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

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

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

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

[0121] It will be appreciated that the features and aspects of the invention described above in relation to the first and other aspects of the invention are equally applicable to embodiments of the invention according to the other aspects of the invention and may be combined with them as appropriate, rather than being limited to the particular combinations described above.

[0122] Various embodiments will now be described in detail, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

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

[0124] In this specification, aspects and features of certain examples and embodiments are discussed / described. Some aspects and features of certain examples and embodiments may be conventionally implemented and will not be discussed / described in detail for the sake of brevity. Thus, it will be understood that unrecited aspects and features of the apparatus and methods discussed in this specification may be implemented in accordance with any conventional technology that implements such aspects and features.

[0125] As mentioned above, the present disclosure relates to, but is not limited to, non-combustion aerosol delivery systems and devices that generate aerosols from aerosol-generating materials (also referred to herein as aerosolizable materials) without the combustion of 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 also be noted that the presence of nicotine in the aerosol-generating materials is not a requirement of the present disclosure. In some examples, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system. In some examples, the non-combustion aerosol delivery system is a hybrid system that uses a combination of aerosol-generating materials (one or more of which may be heated) to generate aerosols. Each aerosol-forming material in such a hybrid system may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some examples, the hybrid system includes liquid or gel aerosol-forming materials as well as solid aerosol-forming materials. The solid aerosol-forming materials may include, for example, tobacco or non-tobacco products.

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

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

[0128] The non-flammable aerosol delivery system typically includes a device portion (also referred to herein as a device) and a consumable / item portion (also referred to herein as an item). The device portion typically includes a power source and a controller. The power source typically may be a power source (e.g., a rechargeable battery).

[0129] In some examples, the non-flammable aerosol delivery system may include an area for receiving or engaging a consumable / article, an aerosol generator (which may or may not be within the consumable / article), an aerosol generation area (which may be within the consumable / article), a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0130] In some examples, consumables / items for use with the non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area (also referred to herein as a reservoir for aerosolizable material), an aerosol generating material transfer component (i.e., a wick such as a pad), an aerosol generator (also referred to herein as an aerosol generating component), an aerosol generating area (also referred to herein as an aerosol generating chamber), a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

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

[0132] The aerosol-generating material may be in the form of, for example, a solid, liquid, or gel, and may or may not include actives and / or flavorings. In some examples, the aerosol-generating material may include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some examples, the amorphous solid may be a dry gel. An amorphous solid is a solid material capable of retaining some fluid, such as a liquid, therein. In some examples, the aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0133] The term "active substance" as used herein may relate to a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, dietary supplements, psychotropic drugs, psychoactive agents. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant.

[0134] The aerosol forming material may include one or more constituents capable of forming an aerosol. In some examples, the aerosol forming material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0135] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0136] As used herein, the term "component" is used to denote a part, portion, unit, module, assembly, or the like of an electronic cigarette or similar device, which may incorporate several smaller parts or elements, possibly within an external housing or wall. An electronic cigarette may be formed or constructed of one or more such components, which may be removably or separably connectable to one another, or may be integrally and permanently joined at the time of manufacture to define the entire electronic cigarette. The present disclosure is applicable to, but is not limited to, a system comprising two components separably connectable to one another, configured as consumable / item components, for example, capable of holding an aerosol generating material (also referred to herein as a cartridge or cartomizer), and a device / control unit having a battery for providing power to operate the elements for generating vapor from the aerosol generating material.

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

[0138] The cartridge assembly 30 comprises a storage compartment (also referred to herein as a reservoir) 3 containing an aerosolizable material including (for example) a liquid formulation from which an aerosol containing, for example, nicotine is generated. By way of example, the aerosolizable material may include around 1-3% nicotine and 50% glycerol, with the remainder being approximately propylene glycol, but may also optionally include other ingredients such as water or flavorings. The storage compartment 3 has the form of a storage tank, a container or receptacle in which the aerosolizable material may be stored so that it is free to move and flow (if liquid) within the confines of the tank. Alternatively, the storage compartment 3 may contain a mass of absorbent material such as wadding or glass fiber that holds the aerosolizable material within its porous structure. The storage compartment 3 may be sealed after filling at the time of manufacture so as to be disposable after consumption of the aerosolizable material, or may have other openings such as an inlet port through which new aerosolizable material can be added. The cartridge assembly 30 also includes an electrical aerosol generation component 4 disposed outside the reservoir tank 3 for generating an aerosol by vaporization of the aerosolizable material. In many instances, the aerosol generation component may be a heating element (heater) that is heated by the passage of an electric current (by resistive or inductive heating) to raise the temperature of the aerosolizable material until it vaporizes. A liquid conduit arrangement such as a wick or other porous element (not shown) may also be provided to deliver the aerosolizable material from the storage compartment 3 to the aerosol generation component 4. The wick may have one or more portions disposed inside the storage compartment 3 such that the aerosolizable material may be absorbed and transferred by wicking or capillary action to other portions of the wick in contact with the aerosol generation component 4. In this way, the aerosolizable material is vaporized and replaced by new aerosolizable material transferred by the wick to the aerosol generation component 4.

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

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

[0141] Typically, the aerosol generating components are at least partially disposed within an aerosol generating chamber that forms part of the airflow channel through the electronic cigarette / system, into which vapor generated by the aerosol generating components is directed and into which air flowing over and around the aerosol generating elements passes, collecting the vapor generated as it condenses to form the required aerosol.

[0142] Also, referring back to FIG. 1, the cartridge assembly 30 includes a mouthpiece 35 having an opening or air outlet through which a user can inhale the aerosol generated by the aerosol generation component 4 and delivered through the air flow channel.

[0143] The power component 20 comprises the electrical components of the e-cigarette 10, in particular the cell 5 (also referred to herein as a battery, which may be rechargeable) that provides power for the aerosol generating component 4. There is also a printed wiring board 28 and / or other electronics or circuitry for controlling the e-cigarette generally. The control electronics / circuitry connects the vapor generating component 4 to the battery 5 when vapor is required, for example in response to a signal from an air pressure sensor or air flow sensor (not shown) that detects a draw on the system 10, where air enters through one or more air inlets 26 in the wall of the power component 20 and flows along an air flow channel. Upon receiving power from the battery 5, the aerosol generating component 4 vaporizes the aerosolizable material delivered from the storage compartment 3 to generate an aerosol, which is then inhaled by the user through an opening in the mouthpiece 35. When the user inhales on the mouthpiece 35, the aerosol is transported to the mouthpiece 35 along an air flow channel (not shown) that connects the air inlet 26 to the air outlet. Thus, an air flow path is defined through the electronic cigarette between the air inlet(s) to the atomizer (which may or may not be present in the power component) and the air outlet in the mouthpiece. In use, the direction of airflow is from the air inlet to the air outlet along this air flow path, and therefore the atomizer can be described as being downstream of the air inlet and upstream of the air outlet.

[0144] In this particular example, the power section 20 and the cartridge assembly 30 are separate parts that are detachable from one another by separation parallel to the longitudinal axis, as shown by the solid arrow in FIG. 1. The components 20, 30 are joined together during use of the device 10 by cooperation of mating elements 21, 31 (e.g., threads, magnetic or bayonet fittings) that provide mechanical and electrical connection between the power section 20 and the cartridge assembly 30. However, this is merely an exemplary configuration, and the various components described above may be distributed differently between the power section 20 and the cartridge assembly 30, and other components and elements may be included. The two parts may be joined end-to-end in a longitudinal configuration as in FIG. 1, or may be in a different configuration, such as a parallel side-by-side arrangement. The system may or may not be generally cylindrical and / or generally longitudinal in shape. The e-cigarette 10 may be intended for disposal and replacement of one or both parts upon exhaustion (e.g., when the reservoir is empty or the battery runs out of charge), or may be intended for multiple uses, enabled by measures such as refilling the reservoir, recharging the battery, or replacing the atomizer. Alternatively, the e-cigarette 10 may be a single device (disposable or refillable / rechargeable) that cannot be separated into two or more parts, in which case all components are contained within a single body or housing. Examples of the present invention are applicable to any of these configurations and other configurations as will be recognized by those of skill in the art.

[0145] As mentioned above, the type of aerosol generating component (such as a heating element) that may be utilized in the atomizer portion of an e-cigarette (the portion configured to generate vapor from a liquid feedstock) combines the functions of heating and liquid delivery by being both electrically conductive (resistive) and porous. However, reference to being electrically conductive (resistive) refers to a component that has the ability to generate heat in response to the flow of electric current therethrough. Such flow may be provided by so-called resistive or inductive heating. One such suitable material is an electrically conductive material such as a metal or alloy formed in sheet-like form, i.e., a planar shape whose thickness is many times smaller than its length or width. Examples in this regard include meshes, webs, grilles, and the like. Meshes may be formed of metal wires or fibers that are cohered into an integral woven or non-woven structure. For example, fibers may be cohered by sintering, where a collection of metal fibers is compressed into a single porous mass by the application of heat and / or pressure. Planar aerosol generating components may define curved surfaces, and in these cases references to the planar aerosol generating components constituting a surface refer to an imaginary plane that constitutes the surface that best fits the entire component.

[0146] These structures can provide suitable sized voids and gaps between the metal fibers to provide capillary forces for wicking of liquids. For this reason, these structures can also be considered porous, since they allow for the absorption and distribution of liquids. Furthermore, the presence of voids and gaps between the metal fibers allows air to spread through the structure. Metals are also electrically conductive and suitable for resistive heating, so heat is generated by the flow of an electric current through a material with electrical resistance. However, this type of structure is not limited to metals, and other conductive materials can be formed as fibers and configured as mesh, grill, or web structures. Examples include ceramic materials, which may or may not be doped with substances intended to adjust the physical properties of the mesh.

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

[0148] The aerosol-generating component may have and / or be formed in any one of the following structures: woven or knitted structures, mesh structures, fabric structures, open-pore fiber structures, open-pore sintered structures, open-pore foams, or open-pore stack structures. The structures are particularly suited to providing a high degree of porosity in the aerosol-generating component, which allows for high efficiency since the heat generated by the aerosol-generating component is primarily used to evaporate the liquid. Porosities of greater than 50% are conceivable in the structures. 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 comprise, for example, a nonwoven fabric, which may be optionally compressible and further cohesively improved by sintering. The open-pore sintered structure may comprise, for example, a granular, fibrous, or cotton-like sintered composite produced by a film casting process. The open-pore stack structure may be produced by, for example, a CVD process, a PVD process, or flame spraying. Open-hole foams are in principle commercially available and can also be obtained in thin micro-pore designs.

[0149] In one embodiment, the aerosol-generating component is formed by a single layer. In one embodiment, the aerosol-generating component has at least two layers, the layers comprising at least one of the following structures: plate, foil, paper, mesh, woven structure, fabric, open-hole fiber structure, open-hole sintered structure, open-hole foam, or open-hole stack structure. For example, the aerosol-generating component can be formed by an electric heating resistor consisting of a metal foil combined with a structure comprising a capillary structure. If the aerosol-generating component is considered to be formed by a single layer, such a layer can be formed by a woven metal wire fabric or a non-woven metal fiber fabric. Conveniently, but not necessarily, the individual layers are connected to each other by a heat treatment such as sintering or welding. For example, the aerosol-generating component may be designed as a sintered composite consisting of one or more layers of stainless steel foil and woven stainless steel wire fabric (materials, e.g., AISI 304 or AISI 316). Alternatively, the aerosol-generating component may be designed as a sintered composite consisting of at least two layers of woven stainless steel wire fabric. The layers may be connected to each other by spot welding or resistance welding. The individual layers may also be mechanically connected to each other. For example, it is also possible to produce two layers of woven wire fabric by simply folding a single layer. Instead of stainless steel, by way of example, heating conductor alloys may be used, in particular NiCr and CrFeAl alloys ("Kanthal"), which have a much higher specific electrical resistance than stainless steel. The material connection between the layers is achieved by heat treatment, so that the layers remain in contact with each other even under adverse conditions, e.g. during heating by the aerosol-generating component and the resulting induced thermal expansion. Alternatively, the aerosol-generating component may be formed by sintering a number of individual fibers together. For this reason, the aerosol-generating component may consist of sintered fibers, such as sintered metal fibers.

[0150] The aerosol generating component may comprise a thin conductive layer of an electrically resistive material, such as platinum, nickel, molybdenum, tungsten or tantalum, which is applied to the surface of the vaporizer by a PVD or CVD process or any other suitable process. In this case, the aerosol generating component may comprise an electrically insulating material (e.g. ceramic). Examples of suitable electrically resistive materials include stainless steels such as AISI 304 or AISI 316, and heating conductor alloys such as DIN material numbers 2,4658, 2,4867, 2,4869, 2,4872, 1,4843, 1,4860, 1,4725, 1,4765 and 1,4767, in particular NiCr alloys and CrFeAl alloys ("Kanthal").

[0151] As mentioned above, the aerosol generating component may be formed from a sintered metal fiber material and may be in the form of a sheet. This type of material may be considered a mesh or irregular lattice, produced by sintering together a randomly aligned configuration or array of spaced apart metal fibers or strands. It is also contemplated that a single layer of fibers may be used, or several layers (e.g. up to 5 layers). By way of example, the metal fibers may have a diameter of 8-12 μm and be configured to give a sheet of 0.16 mm thickness, weighing 100 g / m 2 ~1500g / m 2 (150g / m 2 ~1000g / m 2 , 200g / m 2 ~500g / m 2 , or 200~250g / m 2The aerosol-generating components are spaced apart to produce a material density of 0.1 mm to 0.2 mm (e.g., 0.1 mm to 0.15 mm) and a porosity of 84%. The thickness of the sheet may be in the range of 0.1 mm to 0.2 mm (e.g., 0.1 mm to 0.15 mm). Specific thicknesses include 0.10 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, or 0.1 mm. In general, the aerosol-generating component has a uniform thickness. However, as will be appreciated from the following discussion, the thickness of the aerosol-generating component does not have to be uniform. This may be due, for example, to compression of parts of the aerosol-generating component. It is also possible to vary the porosity of the aerosol-generating component by selecting different diameters and thicknesses of the fibers. For example, the aerosol-generating component may have a porosity of 66% or more, 70% or more, 75% or more, 80% or more, 85% or more, or 86% or more.

[0152] The aerosol-generating component may comprise a generally planar structure including a first and a second surface. The generally planar structure may be in the form of any two-dimensional shape (e.g., circular, semicircular, triangular, square, rectangular, and / or polygonal). Typically, the aerosol-generating component has a uniform thickness.

[0153] The width and / or length of the aerosol generating component may be from about 1 mm to about 50 mm. For example, the width and / or length of a vaporizer may be 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In general, the width of the aerosol generating component may be less than its length. It will be appreciated that the dimensions of the aerosol generating component can vary.

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

[0155] Planar aerosol-generating components (such as heating elements) suitable for use in the systems, devices, and articles disclosed herein may be extruded or cut (such as laser cut) into the desired shape from a larger sheet of porous material. In this case, the extrusion, cutting, or removal of material may create openings in the aerosol-generating component. These openings may affect both the ability of air to pass through the aerosol-generating component and the tendency for electrical current to flow in certain areas.

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

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

[0158] The carrier assembly (e.g., first and second carrier components 101, 102) may be molded from a plastic material with a high glass fiber content (e.g., around 50% or more) for increased rigidity and resistance to high temperatures (e.g., temperatures around 230°C).

[0159] The first and second carrier components 101, 102 may be provided in a variety of forms and sizes. The carrier assembly is configured such that when the two carrier components 101, 102 are brought together to sandwich the aerosol generation component 103, an air flow passage 110 extends down the interior of the carrier assembly and at least partially within which the aerosol generation component 103 is disposed. The air flow passage 110 includes an aerosol generation chamber. The carrier assembly may be elongated in form and may have similar width and length dimensions. Furthermore, the form and size of the air flow passage may vary.

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

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

[0162] The aerosol-generating component 103 may be made of a porous material. For example, the aerosol-generating component 103 may be made of an electrically conductive material. For example, the aerosol-generating component 130 may be made of a single layer. For example, the aerosol-generating component 103 may be made of a woven or knitted structure, a mesh structure, a textile structure, an open-pore fiber structure, an open-pore sintered structure, an open-pore foam, or an open-pore pile structure. For example, the aerosol-generating component 103 may be generally in the form of a sheet. For example, the aerosol-generating component 103 may be made of a sintered metal fiber material and generally in the form of a sheet. Of course, other porous electrically conductive materials may be equally adapted to be used.

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

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

[0165] The aerosol generation component 103 may include one or more openings 200 (e.g., elongated openings). In some examples, the opening(s) 200 may comprise one or more elongated openings extending inwardly from each of the long sides (sides parallel to the longitudinal direction). For example, the elongated openings 200 may extend inwardly by approximately 4.8 mm. For example, the inwardly extending elongated openings may be separated from each other on each side of the aerosol generation component 103 by approximately 5.4 mm, and the slots extending inwardly from the opposing sides may be offset from each other by approximately half this distance. In other words, the slots may be arranged alternately along the longitudinal sides. Other configurations and dimensions are also contemplated. As a result of this arrangement of the slots 200 in the aerosol generation component 103, the current along the aerosol generation component 103 is in effect forced to follow a serpentine path resulting in a concentration of current and therefore power around the ends of the slots. In this regard, due to the presence of the elongated heating section, the aerosol generation component 103 can be configured such that some areas of the aerosol generation component 103 (in this example, the tortuous path) have a tendency for greater current flow than other areas.

[0166] Forcing the current to follow a straight path results in a few large hot areas distributed unevenly throughout the aerosol generating component 103, whereas forcing the current to follow a serpentine path results in more hot areas (also referred to as "hot spots") distributed more evenly throughout the aerosol generating component 103. In this way, the risk of burning the aerosolizable material and / or inadvertent drying of the aerosol generating component 103 may be reduced. Also, a more uniform heat distribution and therefore a more consistent aerosolization (e.g., more consistent particle size) may be achieved.

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

[0168] Those skilled in the art will appreciate that article 100 can be manufactured in a variety of different ways, and the examples described herein are representative, for example, the arrangement of aerosol-generation component 103 in the housing, e.g., between second carrier component 102 and first carrier component 101, can vary.

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

[0170] Of course, in use, the article 100 of FIG. 2 may be surrounded on either side by a reservoir of aerosolizable material (not shown in the drawings). As described, the distance between the first and second carrier components 101, 102 corresponds to the gap G. This gap G is in fluid communication with the reservoir and provides capillary channels (one on each side) that extend along each side of the aerosol generation component 103. For example, in use, the aerosolizable material is fed through the gap G and enters the pores (if present) of the aerosol generation component 103, where it vaporizes, thereby generating a vapor in the aerosol generation chamber. When a user utilizes the system 10, the passing air collects the vapor and generates an aerosol, which is drawn from the aerosol generation chamber along another portion of the air flow path through the system 10 and out the air outlet.

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

[0172] Exemplary aspects of the present disclosure are described below.

[0173] According to one aspect of the present disclosure, an aerosol generating component is disclosed that includes at least one elongated slit, one, more, or all of which have a width of up to 0.3 mm. The inventors have determined that the use of slots (wider than the slits in this context) found in prior art aerosol generating components may result in inadvertent leakage of aerosolizable material. In particular, the slots may act as a leakage path for the aerosolizable material. The inventors have determined that the use of slits narrower than the slots may reduce the risk of inadvertent leakage of aerosolizable material through the aerosol generating component. Similarly, the use of slits may allow for uniform heat distribution throughout the aerosol generating component, as they provide additional electrical current paths. In this manner, more consistent particle sizes and therefore improved aerosolization may be achieved.

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

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

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

[0177] In some examples, one, more, or all of the elongated slits are curved.

[0178] In some examples, the aerosol generation component 103 is substantially planar, and although this configuration is shown in the drawings, it will be appreciated that other shapes are contemplated.

[0179] It should also be appreciated that the configuration of one, more, or all of the elongated slits 200 may vary. In some examples, one, more, or all of the elongated slits 200 include multiple elongated slit portions. In some examples, one, more, or all of the elongated slit portions are substantially straight. In some examples, one, more, or all of the elongated slit portions are curved (e.g., in the plane of a substantially planar aerosol generation component 103 as shown in FIG. 4).

[0180] In some examples, at least two of the elongated slit portions are angled relative to one another. In some examples, at least two of the elongated slit portions may not be parallel to one another. In some examples, at least two of the elongated slit portions are angled obliquely relative to one another. For example, as shown in FIG. 3C, two of the elongated slits 200 each include two slit portions that are angled obliquely relative to one another.

[0181] In some examples, one, more, or all of the elongated slits 200 are open at the periphery of the aerosol generating component 103. For example, Figures 3B, 3C, and 4 show this configuration, i.e., in each of Figures 3B, 3C, and 4, two slits 200 are open at the periphery of the aerosol generating component 103. This configuration is advantageous because it helps to provide an area of ​​high current density while reducing the possibility of inadvertent leakage of aerosolizable material.

[0182] In some instances, one, more than one, or all of the elongated slits 200 are surrounded by the periphery of the aerosol generation component. For example, this configuration is shown in Figures 3A, 3C, and 4, in which many of the elongated slits 200 are surrounded by the periphery of the aerosol generation component 103. By surrounding the elongated slits 200, the elongated slits 200 are less likely to provide a leakage path for aerosolizable material.

[0183] The aerosol generation component 103 may include (e.g., at least one) aerosolizable material supply 103F configured to receive aerosolizable material (e.g., by capillary forces). For example, aerosolizable material supply 103F is shown in Figure 4, where the portion outside each dashed line corresponds to aerosolizable material supply 103F.

[0184] The aerosol generation component 103 may comprise (e.g., at least one) aerosolization portion 103G configured to aerosolize an aerosolizable material. For example, aerosolization portion 103G is shown in Figure 4, where the portion shown between the dashed lines corresponds to aerosolization portion 103G. It is to be understood that, in use, only aerosolization portion 103G may reach a temperature sufficient to aerosolize an aerosolizable material.

[0185] In some examples, the aerosol generating component 103 has a porous and / or permeable structure through which the aerosolizable material can enter, such that in some examples the aerosol generating component 103 can take up the aerosolizable material, which is provided to the aerosolization portion 103F from the aerosolizable material supply portion 103F and aerosolized.

[0186] In some examples, one, more, or all of the elongated slits 200 are provided in the aerosolization portion 103G.

[0187] In some examples, one, more, or all of the elongated slits 200 are located in the aerosolization portion 103G. In some examples, one, more, or all of the elongated slits 200 do not extend into the aerosolizable material supply portion 103F. By providing the slit(s) in this manner, the risk of inadvertent leakage of the aerosolizable material is reduced. At the same time, the slit(s) provide additional electrical current paths, resulting in additional hot spots. Increasing the total number of hot spots improves the heat distribution throughout the aerosol generation components, as the intensity of each hot spot is reduced. This allows for more consistent particle size and therefore improved aerosolization.

[0188] In some examples, one, more, or all of the elongated slits 200 are connected to the elongated slots 201. In such examples, the elongated slits 200 that are connected to the elongated slots 201 may form an elongated opening. In such examples, the slits 200 and the slots 201 may be referred to as a "slit portion" 200 and a "slot portion" 201, respectively.

[0189] It will be appreciated that slits and slots are forms of openings, and it will be appreciated that slots are wider than slits.

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

[0191] In some examples, one, more, or all of the elongated slits 200 are provided in the aerosolizable material supply 103F. In some examples, one, more, or all of the elongated slots 201 are provided in the aerosolization section 103G. Thus, the use of slit(s) 200 in the aerosolizable material supply 103F reduces the risk of leakage of the aerosolizable material (versus the use of slot(s)). The use of slit(s) 200 in the aerosolizable material supply 103F may also increase the storage of the aerosolizable material in the aerosol generating component 103 (versus the use of slot(s)), since less material is removed from the aerosol generating component 103 (versus the use of slot(s)). Furthermore, the use of slit(s) 200 in the aerosolizable material supply eliminates the need for a means to prevent leakage of the aerosolizable material through the slit(s). In contrast, in some aerosol generating components where the slot extends through the aerosolizable material supply (e.g., to the outer periphery of the aerosol generating component), means may be required to prevent leakage of the aerosolizable material through the slot.

[0192] In some instances, one, more than one, or all of the elongated slits 200 extend into the aerosolization portion.

[0193] 4, elongated slit 200 is connected to each elongated slot 201 to form a respective elongated opening. Elongated slit 200 is (at least partially) provided in aerosolizable material supply portion 103F, and elongated slot 201 is provided in aerosolization portion 103G.

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

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

[0196] The aerosol generating component may include any other features as defined herein.

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

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

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

[0200] According to one embodiment, an aerosol generating component is disclosed that comprises at least one curved elongated opening. The curved shape allows the opening to cover a larger surface area (for a given length) compared to a straight elongated opening. Thus, the use of at least one curved elongated opening can improve the amount and / or distribution of aerosol generation. For example, aerosol can be generated over a larger surface area.

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

[0202] 4, the aerosol generation component 103 comprises at least one curved elongated opening 200, 201. In some examples, one, more, or all of the curved elongated openings 200, 201 have an increasing curvature from one end of the opening 200, 201 to the other end of the opening 200, 201. The increase in curvature may be continuous. The increase in curvature may start midway along the opening 200, 201.

[0203] In some examples, one, more, or all of the curved elongated openings 200, 201 are curved along at least a portion of their length.

[0204] In some instances, one, more, or all of the curved elongated openings 200, 201 are curved along substantially their entire length.

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

[0206] In some examples, one, more, or all of the curved elongated openings 200, 201 have a substantially constant width.

[0207] In some examples, one, more, or all of the curved elongate openings 200, 201 comprise curved portions (or at least partially curved portions) connected to substantially straight portions.

[0208] For example, as shown in Figure 4, there are four openings 200, 201. Two of the openings 200, 201 each include an at least partially curved portion 201 connected to a substantially straight portion 200. Another two of the openings 200, 201 each include an at least partially curved portion 200 connected to a substantially straight portion 201.

[0209] In some examples, one, more, or all of the curved elongated openings 200, 201 comprise a slot portion 201. In some examples, one, more, or all of the curved elongated openings 200, 201 comprise a slit portion 200. In some examples, one, more, or all of the curved elongated openings 200, 201 comprise a slot portion 201 connected to a slit portion 200. It is to be understood that the slot portion 201 has a greater width than the slit portion 200.

[0210] Of course, the slot portion (also referred to as a "slot") is wider than the slit portion (also referred to as a "slit").

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

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

[0213] It is to be understood that the joint / connection between each slot portion 201 and slit portion 200 may be of various widths intermediate the slot portion 201 and the slit portion 200 .

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

[0215] In some examples, one, more or all of the curved elongated openings 200, 201 are open at the periphery of the aerosol generation component 103. As shown in Figure 4, two of the openings 200, 201 are open at the periphery of the aerosol generation component 103.

[0216] In some examples, one, more or all of the curved elongated openings 200, 201 are surrounded by the periphery of the aerosol generation component 103. As shown in Figure 4, two of the openings 200, 201 are surrounded by the periphery of the aerosol generation component 103.

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

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

[0219] In some instances, one, more, or all of the slots 201 are located in the aerosolization portion 103G. In some instances, one, more, or all of the slots 201 do not extend into the aerosolizable material supply portion 103F.

[0220] In some instances, one, more, or all of the slits 200 are located in the aerosolizable material supply 103F. In some instances, one, more, or all of the slits 200 extend into the aerosolization portion.

[0221] 4, each slot 201 is provided in aerosolization unit 103G, and two slits 200 are provided in aerosolizable material supply unit 103F and extend into aerosolization unit 103G, such that substantially the entirety of two slits 200 are provided in aerosolizable material supply unit 103F. Variations on this configuration are also contemplated.

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

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

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

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

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

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

[0228] According to one aspect, an article for use in a non-flammable aerosol delivery system is disclosed, the article comprising: a housing; and an aerosol generating component having at least one elongated slot and at least partially contained within the housing, the housing defining a capillary gap through which aerosolizable material can be delivered to the aerosol generating component, wherein the capillary gap and one, more than one, or all of the elongated slots do not overlap.

[0229] By providing the elongated slot and the capillary gap with no overlap, the possibility of leakage of aerosolizable material through the elongated slot is reduced, for example leakage of aerosolizable material may be more pronounced if the capillary gap coincides with or overlaps with the elongated slot.

[0230] In some examples, one, more, or all of the elongated slots 201 are disposed within the capillary gap. As such, the elongated slots 201 are disposed toward the center of the aerosol generation element 103, away from the capillary gap. This configuration further reduces the risk of leakage of the aerosolizable material.

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

[0232] In some examples, one, more than one, or all of the elongated slots 201 constitute part of an elongated opening of the aerosol generation component 103 (in which case the elongated slots may be referred to as "elongated slot portions"). Thus, the aerosol generation component 103 may comprise at least one elongated opening having at least one elongated slot 201.

[0233] In some examples, the aerosol generation component 103 comprises at least one elongated slit 200. In some examples, one, more than one, or all of the elongated slits 200 may form part of an elongated opening of the aerosol generation component 103 (in which case the elongated slits may be referred to as "elongated slit portions").

[0234] In some examples, one, more, or all of the elongated slots 201 are connected to the elongated slits 200. This may be to form elongated openings 200, 201. Such a configuration is shown in FIG. 4 and described elsewhere herein.

[0235] In some examples, one, more, or all of the elongated slits 200 and the capillary gaps overlap and / or coincide. Providing the elongated slits in this location provides an additional current path, allowing for increased resistance and improved heating while maintaining a reduced risk of leakage through the aerosol generation component 103.

[0236] One, more, or all of the elongated slots 200 and one, more, or all of the elongated slits 200 may be as defined elsewhere herein.

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

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

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

[0240] In some examples, one, more, or all of the elongated slots 201 are located in the aerosolization portion 103F.

[0241] In some instances, one, more, or all of the elongated slits 200 are provided in the aerosolizable material supply 103G.

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

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

[0244] Of course, the housing may be provided in various forms. For example, the housing may comprise a carrier assembly. The housing (e.g., carrier assembly) may comprise a first carrier component 101 and a second carrier component 102. The first carrier component 101 and the second carrier component 102 may define a capillary gap. For example, the capillary gap may be defined by a distance between the first carrier component 101 and the second carrier component 102 when the first and second carrier components 101, 102 are attached together. The aerosol generation component 103 may be at least partially disposed between the first carrier component 101 and the second carrier component 102. The first carrier component 101 and the second carrier component 102 may be as described elsewhere herein.

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

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

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

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

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

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

Claims

1. The aerosol generation component includes at least one curved elongated opening.

2. The aerosol generation component of claim 1 , wherein one, more, or all of the curved elongated openings have an increasing curvature from one end of the opening to the other end of the opening.

3. 3. The aerosol generation component of claim 1 or 2, wherein one, more or all of the curved elongated openings are curved along at least a portion of their length.

4. 4. An aerosol generation component according to any one of claims 1 to 3, wherein one, more or all of the curved elongate openings are curved along substantially their entire length.

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

6. 6. An aerosol generation component according to any one of claims 1 to 5, wherein one, more or all of the curved elongated openings comprise a curved section connected to a straight section.

7. An aerosol generation component according to any one of claims 1 to 6, wherein one, more than one or all of the curved elongated openings comprise a slot portion connected to a slit portion.

8. 8. The aerosol generating component of claim 7, wherein the width of the slot is greater than 0.3 mm and the width of the slit is a maximum of 0.3 mm.

9. 9. An aerosol generating component according to any one of the preceding claims, wherein one, several or all of the curved elongated openings are open at the periphery of the aerosol generating component.

10. 10. An aerosol generating component according to any one of the preceding claims, wherein one, several or all of the curved elongated openings are surrounded by the periphery of the aerosol generating component.

11. 11. The aerosol generating component of claim 1, comprising an aerosolizable material supply configured to receive and aerosolize an aerosolizable material, and an aerosolizer configured to aerosolize the aerosolizable material.

12. The aerosol generating component of claim 11 , wherein one, more, or all of the curved elongated openings comprise a slot portion connected to a slit portion, and one, more, or all of the slot portions are provided in the aerosolization portion.

13. 13. The aerosol generating component of claim 11 or 12, wherein one, more or all of the curved elongated openings comprise a slot portion connected to a slit portion, and one, more or all of the slit portions are provided in the aerosolizable material supply portion.

14. An aerosol generating component according to any one of claims 1 to 13, comprising one or more electrical connectors.

15. An aerosol-generating component according to any preceding claim, wherein the aerosol-generating component is formed from a porous material.

16. An aerosol generating component according to any preceding claim, wherein the aerosol generating component is formed from an electrically conductive material.

17. An aerosol-generating component according to any preceding claim, wherein the aerosol-generating component is formed from a single layer.

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

19. An article comprising an aerosol generating component according to any one of claims 1 to 18, and one or more of an aerosol forming chamber and a reservoir of aerosolizable material.

20. 20. A non-flammable aerosol delivery system comprising the article of claim 19 and a device comprising one or more of a power source and a controller.

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