Delivery System

Abstract

The present invention relates to an article for use as part of a non-combustion aerosol delivery system comprising a housing, an aerosol generating component, and an aerosol-generating material transport component, wherein the aerosol generating component and the aerosol-generating material transport component are contained within the housing, and the aerosol generating component is biased against the aerosol-generating material transport component.

Description

[Technical Field]

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

[0002] Non-combustion aerosol delivery systems that generate aerosols for inhalation by a user are known in the art. Such systems typically include an aerosol generator capable of converting an aerosolizable material into an aerosol. In some examples, the generated aerosol is a condensation aerosol, in which the aerosolizable material is first vaporized and then allowed to condense into an aerosol. In other examples, the generated aerosol is an aerosol resulting from atomization of the aerosolizable material. Such atomization can be effected mechanically, for example, by subjecting the aerosolizable material to vibration to form small particles of the material that are entrained in an airflow. Alternatively, such atomization can be effected electrostatically or by other methods, such as using pressure.

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

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

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

[0006] According to one aspect of the present disclosure, there is provided an article for use as part of a non-combustion aerosol delivery system, comprising: a housing having at least one air inlet; a substantially planar aerosol-generating component contained within a housing; Equipped with the at least one air inlet is configured to direct air towards the aerosol-generation component in an inlet airflow direction, and the plane of the substantially planar aerosol-generation component is inclined obliquely to the inlet airflow direction; The goods are provided.

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

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

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

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

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

[0012] In some examples, the aerosol-generating component is at least partially disposed within the aerosol-forming chamber.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0032] In some examples, the aerosol-generating component is at least partially disposed within the aerosol-forming chamber.

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

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

[0035] In some examples, elongated apertures are provided between adjacent elongated heating portions.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0051] In some examples, elongated apertures are provided between adjacent elongated heating portions.

[0052] In some examples, the aerosol-generating component is configured such that the airflow moves perpendicular to a boundary between at least two generally planar portions that lie in different planes.

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

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

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

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

[0057] In some examples, the aerosol-generating component is disposed at least partially within the aerosol-forming chamber.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0074] In some examples, the aerosol-generating component is at least partially disposed within the aerosol-forming chamber.

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

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

[0077] In some examples, elongated apertures are provided between adjacent elongated heating portions.

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

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

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

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

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

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

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

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

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

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

[0088] A4. An article according to clause A2 or A3, wherein one or both of the magnetic material and the corresponding magnetic material is a temporary magnet or an electromagnet.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0143] Various embodiments will now be described in detail, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0144] [Figure 1] 1 is a schematic diagram of an aerosol delivery system according to the present disclosure. [Figure 2] 1 is a diagram of an article for use as part of an aerosol delivery system according to the present disclosure. [Figure 3] FIG. 3 is an exploded view of the article of FIG. 2. [Figure 4A] FIG. 1 is a schematic diagram of an exemplary aerosol-generating component according to the present disclosure. [Figure 4B] FIG. 1 is a schematic diagram of an exemplary aerosol-generating component according to the present disclosure. [Figure 4C] FIG. 1 is a schematic diagram of an exemplary aerosol-generating component according to the present disclosure. [Figure 5] 5A and 5B are schematic diagrams of exemplary aerosol-generating components according to the present disclosure. [Figure 5C] FIG. 1 is a schematic diagram of an exemplary aerosol-generating component according to the present disclosure. [Figure 5D] FIG. 1 is a schematic diagram of an exemplary aerosol-generating component according to the present disclosure. [Figure 6] 1 is a schematic diagram of an exemplary article for use as part of an aerosol delivery system according to the present disclosure (although various portions of the article have been omitted for clarity); FIG. DETAILED DESCRIPTION OF THE INVENTION

[0145] Aspects and features of particular examples and embodiments are discussed / described herein. Some aspects and features of particular examples and embodiments may be conventionally implemented and will not be discussed / described in detail for the sake of brevity. Accordingly, it will be understood that aspects and features of the apparatus and methods discussed herein but not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

[0146] As mentioned above, the present disclosure relates to (but is not limited to) non-combustion aerosol delivery systems and devices that generate aerosols from aerosol-generating materials (or aerosolizable materials) without burning the aerosol-generating materials. Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (which generate aerosols using a combination of aerosol-generating materials). In some examples, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement of the present disclosure. In some examples, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system. In some examples, the non-combustion aerosol delivery system is a hybrid system that generates aerosols using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials 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, hybrid systems include a liquid or gel aerosol-forming material and a solid aerosol-forming material, which may include, for example, tobacco or a non-tobacco product.

[0147] Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may be used, but it will be understood that these terms may be used interchangeably with non-combustion aerosol (vapor) delivery systems or devices such as those described above.

[0148] In some examples, the present disclosure relates to consumables for holding aerosol-generating materials, the consumables being configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0149] A non-combustion aerosol delivery system typically includes a device portion (i.e., a device) and a consumable / item portion (i.e., an item). The device portion typically includes a power source and a controller. The power source may typically be a power source, such as a rechargeable battery.

[0150] In some examples, the non-combustion aerosol delivery system may include an area for receiving or engaging a consumable / item, an aerosol generator (which may or may not be within the consumable / item), an aerosol-generating area (which may be within the consumable / item), a housing, a mouthpiece, a filter, and / or an aerosol modifier.

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

[0152] The systems described herein typically generate an inhalable aerosol by vaporizing an aerosol-generating material, which may include one or more active ingredients, one or more flavors, one or more aerosol-forming materials, and / or one or more other functional materials.

[0153] The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active agent and / or a flavoring. In some examples, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some examples, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some examples, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% by weight of amorphous solid, up to about 90%, 95%, or 100% by weight of amorphous solid.

[0154] The term "active substance" as used herein may refer to a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive substances. 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 components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant.

[0155] The aerosol-forming material may include one or more components capable of forming an aerosol. In some examples, the aerosol-forming material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0156] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0157] As used herein, the term "component" refers to a part, section, unit, module, assembly, or the like of an electronic cigarette or similar device that incorporates several smaller parts or elements, which may be within an external housing or wall. An electronic cigarette may be formed or constructed from one or more such components, which may be removably or separably connectable to one another or may be permanently joined to one another during manufacturing to define the entire electronic cigarette. The present disclosure is applicable (but not limited to) to systems comprising two removably connectable components, for example, a consumable / item component (also referred to herein as a cartridge or cartomizer) capable of holding an aerosol-generating material, and a device / control unit having a battery for providing power to operate the elements for generating vapor from the aerosol-generating material.

[0158] Aspects and features of particular examples and embodiments are discussed / described herein. Some aspects and features of particular examples and embodiments may be conventionally implemented and will not be discussed / described in detail for the sake of brevity. Accordingly, it will be understood that aspects and features of the apparatus and methods discussed herein but not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

[0159] As mentioned above, the present disclosure relates to (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 combusting the aerosol-generating materials. Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (which generate aerosols using a combination of aerosol-generating materials). In some examples, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement of the present disclosure. In some examples, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system. In some examples, the non-combustion aerosol delivery system is a hybrid system that generates aerosols using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials in such a hybrid system may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some examples, hybrid systems include a liquid or gel aerosol-forming material and a solid aerosol-forming material, which may include, for example, tobacco or a non-tobacco product.

[0160] Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may be used, but it will be understood that these terms may be used interchangeably with non-combustion aerosol (vapor) delivery systems or devices such as those described above.

[0161] In some examples, the present disclosure relates to consumables for holding aerosol-generating materials, the consumables being configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0162] A non-combustion aerosol delivery system typically includes a device portion (also referred to herein as a device) and a consumable / item portion (also referred to herein as an article). The device portion typically includes a power source and a controller. The power source may typically be a power source, such as a rechargeable battery.

[0163] In some examples, the non-combustion aerosol delivery system may include an area for receiving or engaging a consumable / item, an aerosol generator (which may or may not be within the consumable / item), an aerosol-generating area (which may be within the consumable / item), a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0164] In some examples, consumables / items for use with non-combustion aerosol delivery devices may include aerosol-generating material, an aerosol-generating material storage region (which may also be referred to herein as a reservoir of aerosolizable material), an aerosol-generating material transfer component (e.g., a wick such as a pad), an aerosol generator (which may also be referred to herein as an aerosol-generating component), an aerosol-generating region (which may also be referred to herein as an aerosol-generating chamber), a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0165] The systems described herein typically generate an inhalable aerosol by vaporizing an aerosol-generating material, which may include one or more active ingredients, one or more flavors, one or more aerosol-forming materials, and / or one or more other functional materials.

[0166] The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active agent and / or a flavoring. In some examples, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some examples, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some examples, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% by weight of amorphous solid, up to about 90%, 95%, or 100% by weight of amorphous solid.

[0167] The term "active substance" as used herein may refer to a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive substances. 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 components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant.

[0168] The aerosol-forming material may include one or more components capable of forming an aerosol. In some examples, the aerosol-forming material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0169] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0170] As used herein, the term “component” refers to a part, section, unit, module, assembly, or the like of an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly within an external housing or wall. An electronic cigarette may be formed or constructed from one or more such components, which may be removably or separably connectable to one another or may be permanently joined to one another during manufacturing to define the entire electronic cigarette. The present disclosure is applicable (without being limited thereto) to systems comprising two components removably connectable to one another, configured, for example, as a consumable / item component (also referred to herein as a cartridge or cartomizer) capable of holding an aerosol-generating material, and as a device / control unit having a battery for providing power to operate the elements for generating vapor from the aerosol-generating material.

[0171] 1 is a highly schematic illustration (not to scale) of an exemplary aerosol / vapor delivery system, such as an e-cigarette 10. The e-cigarette 10 may have a generally cylindrical shape extending along a longitudinal axis indicated by the dashed line, and comprises two main components: a control or power component or section 20 (also referred to herein as a device), and a cartridge assembly or section 30 (also referred to herein as an article, consumable, cartomizer, or cartridge), which operates as a vapor-generating component.

[0172] The cartridge assembly 30 includes a storage compartment 3 (also referred to herein as a reservoir) containing aerosolizable material containing, for example, a liquid formulation from which an aerosol is generated, e.g., containing nicotine. By way of example, the aerosolizable material may contain approximately 1-3% nicotine and 50% glycerol, with the remainder approximately propylene glycol, and possibly other ingredients such as water or flavorings. The storage compartment 3 has the form of a storage tank, a container or receptacle capable of storing the aerosolizable material such that the aerosolizable material moves and flows freely (if liquid) within the tank. Alternatively, the storage compartment 3 may contain a quantity of absorbent material, such as wadding or glass fiber, that holds the aerosolizable material within its porous structure. The storage compartment 3 may be filled and sealed during manufacture so that it is disposable after consumption, or it may have an inlet port or other opening 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 vaporizing the aerosol-generating material. In many devices, the aerosol-generation component may be a heating element (heater) that is heated by the passage of an electric current (via resistive or inductive heating) to increase the temperature of the aerosol-generating material until it evaporates. A liquid conduit arrangement, such as a wick or other porous element (not shown), may be provided to deliver the aerosol-generating material from the storage compartment 3 to the aerosol-generating component 4. The wick may have one or more portions disposed inside the storage compartment 3 that can absorb the aerosol-generating material and transfer it by wicking or capillary action to another portion of the wick that contacts the aerosol-generating component 4. This vaporizes the aerosol-generating material and replaces it with new aerosol-generating material transferred by the wick to the aerosol-generating component 4.

[0173] The combination of heater and wick, or other arrangement of parts that perform the same function, may be referred to as an atomizer or atomizer assembly. Various designs are possible in which the parts may be arranged differently compared to the highly schematic illustration of Figure 1. For example, the wick may be an entirely separate element from the aerosol-generating component, or the aerosol-generating component may be porous and configured to directly perform the wicking function (e.g., by taking the form of a suitable electrically resistive mesh or capillary body).

[0174] In some cases, the conduit for delivering liquid for vapor generation may be formed at least in part from one or more slots, tubes, or channels between the storage compartment and the aerosol-generating component, which are narrow enough to assist capillary action in drawing source liquid from the storage compartment and providing it for vaporization. In general, an atomizer can be thought of as an aerosol-generating component capable of generating vapor from an aerosolizable material delivered to it, and a liquid conduit (pathway) capable of delivering or transporting liquid from the storage compartment or similar liquid reservoir to the aerosol-generating component by capillary forces.

[0175] Typically, the aerosol-generating components are at least partially disposed within an aerosol-generating chamber that forms part of the airflow channel through the electronic cigarette / system. Vapor generated by the aerosol-generating components is forced into this chamber, and as air flows through the chamber and over and around the aerosol-generating components, the aerosol-generating components collect and condense the generated vapor to form the required aerosol.

[0176] Returning to Figure 1, cartridge assembly 30 also includes a mouthpiece 35 having an opening or air outlet through which a user can inhale the aerosol generated by aerosol generating component 4 and delivered through the airflow channel.

[0177] The power component 20 includes a cell or battery 5 (also referred to herein as a battery, which may be rechargeable) for powering the electrical components of the e-cigarette 10, particularly the aerosol-generation component 4. Additionally, there is a printed circuit board 28 and / or other electronics or circuitry for overall control of the e-cigarette. The control electronics / circuitry connects the vapor-generation component 4 to the battery 5 when vapor is needed, for example, in response to a signal from an air pressure or airflow sensor (not shown) that detects inhalation on the system 10, where air enters through one or more air inlets 26 in the wall of the power component 20 to flow along an airflow channel. When the aerosol-generation component 4 receives power from the battery 5, it vaporizes the aerosolizable material delivered from the storage compartment 3 to generate an aerosol, which is then inhaled by the user through an opening in the mouthpiece 35. The aerosol is transported to the mouthpiece 35 along an airflow channel (not shown) connecting the air inlet 26 to the air outlet when the user inhales on the mouthpiece 35. Thus, an airflow path through the electronic cigarette is defined between the air inlet to the atomizer (which may or may not be in the power component) and the air outlet in the mouthpiece. In use, the airflow direction along this airflow path is from the air inlet to the air outlet, and so the atomizer can be described as being downstream of the air inlet and upstream of the air outlet.

[0178] In this particular example, the power section 20 and cartridge assembly 30 are separate parts that can be detached from one another by separating them in a direction parallel to the longitudinal axis, as shown by the solid arrows in FIG. 1 . The components 20, 30 are joined together by cooperating engaging elements 21, 31 (e.g., threaded, magnetic, or bayonet fittings) that provide a mechanical and electrical connection between the power section 20 and cartridge assembly 30 when the device 10 is in use. However, this is merely an exemplary arrangement, and various components may be distributed differently between the power section 20 and cartridge assembly section 30, and other components and elements may be included. The two sections may be connected to one another end-to-end in a longitudinal configuration as in FIG. 1 , or may be connected in a different configuration, such as a parallel side-by-side arrangement. The system may or may not be generally cylindrical and / or may have a generally longitudinal shape. Either or both sections may be intended to be disposed of and replaced when depleted (e.g., when the reservoir is empty or the battery is dead), or may be intended to allow multiple uses by actions such as refilling the reservoir, recharging the battery, or replacing the atomizer. Alternatively, the e-cigarette 10 may be a unitary device (disposable or refillable / rechargeable) that cannot be separated into two or more parts, in which case all components are contained within a single body or housing. Embodiments and examples of the present invention are applicable to any of these and other configurations as will be recognized by those skilled in the art.

[0179] As mentioned above, types of aerosol-generating components, such as heating elements, that can be utilized in the atomization portion of an electronic cigarette (the portion configured to generate vapor from a source liquid) combine the functions of heating and liquid delivery by being both electrically conductive (electrically resistive) and porous. Note that reference to being electrically conductive (electrically resistive) here refers to a component capable of generating heat in response to the flow of electrical current therethrough. Such flow can be imparted via so-called resistive or inductive heating. One example of a suitable material for this purpose is a conductive material, such as a metal or metal alloy, formed in a sheet-like form, i.e., a planar shape having a thickness many times smaller than its length or width. Examples of this would be a mesh, web, grill, or the like. A mesh may be formed from metal wires or fibers woven together, or may be aggregated into a nonwoven structure. For example, the fibers may be aggregated by sintering, in which heat and / or pressure is applied to a collection of metal fibers to compress them into a single porous mass. It is possible for a planar aerosol generating component to define a curved plane, and in these instances, reference to a planar aerosol generating component forming a plane means an imaginary flat plane that forms a best fit plane through the component.

[0180] These structures can provide appropriately sized voids and gaps between the metal fibers to create capillary forces for liquid wicking. Therefore, these structures can also be considered porous, allowing for liquid uptake and distribution. Furthermore, the presence of voids and gaps between the metal fibers allows air to permeate the structure. Metals are also electrically conductive and therefore suitable for resistive heating, whereby current flowing through a material with electrical resistance generates heat. However, this type of structure is not limited to metals; other conductive materials can be formed into fibers and then into 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.

[0181] This type of planar sheet-like porous aerosol-generating component can be positioned within an electronic cigarette within an aerosol-generating chamber that forms part of the airflow channel. The aerosol-generating component can be oriented within the chamber so that airflow through the chamber can flow in a surface direction, i.e., approximately parallel to the plane of the generally planar sheet-like aerosol-generating component. An example of such a configuration can be found in International Publication Nos. 2010 / 045670 and 2010 / 045671, the contents of which are incorporated herein by reference in their entireties. Thus, air can flow over the heating element and collect vapor, resulting in highly effective aerosol generation. Alternatively, the aerosol-generating component can be oriented within the chamber so that airflow through the chamber can flow in a direction generally transverse to the surface direction, i.e., approximately perpendicular to the plane of the generally planar sheet-like aerosol-generating component. An example of such a configuration can be found in International Publication No. 2018 / 211252, the contents of which are incorporated herein by reference in their entireties.

[0182] The aerosol-generating component may have any one of the following structures: woven, mesh, fabric, open-pore fiber, open-pore sintered, open-pore foam, or open-pore stack structure. These structures are particularly suited to providing an aerosol-generating component with a high degree of porosity. A high degree of porosity can ensure that the heat generated by the aerosol-generating component is primarily used to evaporate the liquid, resulting in high efficiency. Porosities of more than 50% may be envisaged by the structure. In one embodiment, the porosity of the aerosol-generating component is 50% or more, 60% or more, or 70% or more. Open-pore fiber structures may, for example, consist of nonwoven fabrics, which may optionally be compressed and further sintered to improve cohesion. Open-pore sintered structures may, for example, consist of granular, fibrous, or cotton-like sintered composites produced by film casting. Open-pore stacked structures may, for example, be produced by CVD, PVD, or flame spraying. Open-pore foams are, in principle, commercially available and can even be obtained with thin pore designs.

[0183] In one embodiment, the aerosol-generating component has at least two layers, each of which comprises at least one of the following structures: plate, foil, paper, mesh, woven structure, fabric, open-pore fiber structure, open-pore sintered structure, open-pore foam, or open-pore stack structure. For example, the aerosol-generating component can be formed by an electrical heating resistor consisting of a metal foil combined with a structure containing a capillary structure. When the aerosol-generating component is considered to be formed from a single layer, such a layer can be formed from a metal wire cloth or a nonwoven metal fiber cloth. The individual layers are preferably, but not necessarily, connected to each other by a heat treatment such as sintering or welding. For example, the aerosol-generating component can be designed as a sintered composite consisting of a stainless steel foil and one or more layers of stainless steel wire cloth (e.g., AISI 304 or AISI 316 material). Alternatively, the aerosol-generating component can be designed as a sintered composite consisting of at least two layers of stainless steel wire cloth. The layers can be connected to each other by spot welding or resistance welding. The individual layers can also be mechanically connected to each other. For example, a double-layer wire fabric can be produced by simply folding a single layer. Instead of stainless steel, for example, a heating conductor alloy, particularly a NiCr alloy or a CrFeAl alloy called "Kanthal," which has an even higher specific electrical resistance than stainless steel, can also be used. The material connection between the layers is achieved by heat treatment, so that the layers maintain contact with each other even under adverse conditions, such as during heating by the aerosol-generating component and the resulting thermal expansion. Alternatively, the aerosol-generating component can be formed by sintering multiple individual fibers together. Thus, the aerosol-generating component can be composed of sintered fibers, such as sintered metal fibers.

[0184] The aerosol-generating component may comprise a thin conductive layer of an electrically resistive material, such as platinum, nickel, molybdenum, tungsten, or tantalum, applied to the vaporizer surface by PVD, CVD, or any other suitable method. In this case, the aerosol-generating component may comprise an electrically insulating material, such as ceramic. Examples of suitable electrically resistive materials include stainless steels such as AISI 304 or AISI 316, and heating conductor alloys, particularly NiCr alloys and CrFeAl alloys such as DIN material numbers 24658, 24867, 24869, 24872, 14843, 14860, 14725, 14765, and 14767, known as "Kanthal."

[0185] As mentioned above, the aerosol-generating component may be formed from a sintered metal fiber material, which may be in the form of a sheet. This type of material can be thought of as a mesh or irregular grid, created by sintering together a randomly aligned arrangement or array of spaced apart metal fibers or wires. A single layer of fibers, or several layers, e.g., up to five layers, may be used. By way of example, the metal fibers may have a diameter of 8-12 μm, arranged to give a sheet 0.16 mm thick, and weighing 100 g / m². 2 ~1500g / m 2 , e.g., 150 g / m 2 ~1000g / m 2 , 200g / m 2 ~500g / m 2 , or 200-250g / m 2The fibers may be 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 sheet thickness may also 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. Generally, the aerosol-generating component has a uniform thickness. However, it will be understood from the following description that the thickness of the aerosol-generating component may vary. This may be due, for example, to portions of the aerosol-generating component undergoing compression. Different fiber diameters and thicknesses can be selected to vary the porosity of the aerosol-generating component. For example, the aerosol-generating component may have a porosity of 66% or more, or 70% or more, or 75% or more, or 80% or more, or 85% or more, or 86% or more.

[0186] The aerosol-generating component may form a substantially planar structure including a first and a second surface. The substantially planar structure can take the form of any two-dimensional shape, such as a circle, semicircle, triangle, square, rectangle, and / or polygon. Generally, the aerosol-generating component has a uniform thickness.

[0187] The width and / or length of the aerosol-generating component may be from about 1 mm to about 50 mm. For example, the width and / or length of the vaporizer may be 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. The width may generally be smaller than the length of the aerosol-generating component.

[0188] If the aerosol-generating component is made of an electrically resistive material, an electric current can flow through the aerosol-generating component to generate heat (so-called Joule heating). In this regard, the electrical resistance of the aerosol-generating component can be selected appropriately. For example, the aerosol-generating component may have an electrical resistance of 2 ohms or less, such as 1.8 ohms or less, such as 1.7 ohms or less, such as 1.6 ohms or less, such as 1.5 ohms or less, such as 1.4 ohms or less, such as 1.3 ohms or less, such as 1.2 ohms or less, such as 1.1 ohms or less, such as 1.0 ohms or less, such as 0.9 ohms or less, such as 0.8 ohms or less, such as 0.7 ohms or less, such as 0.6 ohms or less, such as 0.5 ohms or less. Parameters of the aerosol-generating component, such as the material, thickness, width, length, and porosity, can be selected to provide the desired resistance. In this regard, a relatively low resistance facilitates higher power draw from the power source, which may be preferable for achieving high-speed aerosolization. On the other hand, the resistance should not be so low as to compromise the integrity of the aerosol generator, for example, the resistance should not be lower than 0.5 ohms.

[0189] Planar aerosol-generating components, such as heating elements, suitable for use in the systems, devices, and articles disclosed herein can be formed by stamping or cutting (e.g., laser cutting) the required shape from a larger sheet of porous material. This may involve punching, cutting, or otherwise removing material to form openings in the aerosol-generating component. These openings can affect both the ability of air to pass through the aerosol-generating component and the rate at which electrical current flows through a particular area.

[0190] FIG. 2 is a diagram of an exemplary article 100 according to the present disclosure. The article 100 comprises a housing. In this particular example, the housing comprises an outer housing 110 and an inner housing 120. The outer housing 110 is formed by first and second outer housing components 110a and 110b being integrated together. While the specific appearance of the outer housing 110 is not limited, in this particular example, the outer housing 110 has a multi-faceted surface. The housing, e.g., the outer housing 110, can include at least one outlet 115. In this particular example, there are two outlets 115. The outlets 115 are for conveying the aerosol generated within the article 100 to the user's mouth. Thus, in the example shown in FIG. 2, the outer housing 110 also forms the mouthpiece of the article.

[0191] First outer housing component 110a mates with second outer housing component 110b to form outer housing 110. In this particular example, components 110a, 110b mate with one another via a snap-fit ​​arrangement. In particular, resilient tabs 111 (only one side of which is visible in FIG. 2 ) of second outer housing component 110b snap into corresponding receiving apertures 112 of first outer housing component 110a. The exact locations of the tabs and apertures are not limited, and it will be understood that, in fact, the tabs may be formed in outer housing component 110a and the apertures may be formed in outer housing component 110b.

[0192] Referring to FIG. 3 , the first outer housing component 110a is shown separated from the second outer housing component 110b to reveal the inner housing component 120, the aerosol-generating component 130 (which may be an electrically resistive metal heater), the flow regulator 140, and the pad 150. The inner housing component 120 may be configured to define a storage area 121 for an aerosolizable material (not shown). The inner housing component 120 may be at least partially sleeved inside the first outer housing component 110a. Thus, the inner housing component 120 may be at least partially surrounded by the first outer housing component 110a. The inner housing component 120 can be connected to the first outer housing component 110a (e.g., they may be attached to each other or part of the same molding). The inner housing component 120 can have an open end 122 that mates with the flow regulator 140. Open end 122 and flow regulator 140 together can define a path for aerosolizable material to flow from storage area 121 to pad 150. An optional mouthpiece (not shown) may be sleeved over the outside of first outer housing component 110a (or the outer housing may form the mouthpiece).

[0193] The flow regulator 140 may include a recess 141 that can receive the open end 122 of the inner housing component 120. The recess 141 may include one or more openings 142 that allow the flow of aerosolizable material through the flow regulator. In this particular example, the openings are slot-shaped, but it will be understood that one or more of the openings may have a different cross-section, such as circular, elliptical, or polygonal. Furthermore, the cross-sectional area of ​​the opening(s) 142 may vary throughout the length of the flow regulator 140. Thus, the opening(s) 142 may have a larger cross-sectional area toward the liquid storage region compared to the cross-sectional area toward the pad 150. The flow regulator 140 may include an annular seal 143 around its periphery that functions to inhibit the escape of aerosolizable material from the interface between the inner housing component 120 and the flow regulator 140. The flow regulator 140 may include a surface against which the aerosol generating component 130 can be biased, thus potentially functioning as a heater support.

[0194] Pad 150 may be formed of a capillary material suitable for holding aerosolizable material. In particular, as the aerosolizable material flows through flow regulator 140, pad 150 may become saturated with the aerosolizable material. However, the capillary nature of pad 150 inhibits leakage of the aerosolizable material from pad 150. Aerosol-generating component 130 may be positioned in close proximity to pad 150 such that when aerosol-generating component 130 is energized (resistive heating in this particular example), aerosolizable material present within pad 150 is vaporized. As noted above, pad 150 and aerosol-generating component 130 may be combined into a single component.

[0195] In this particular example, the aerosol-generating component 130 is positioned toward the second outer housing component 110b. Electrical contacts (e.g., pins) 116 on the outer housing component 110b may contact the aerosol-generating component 130 at electrical connectors (e.g., tabs) 130C to allow electrical current to flow through the aerosol-generating component 130 during operation of the system.

[0196] The second outer housing component 110b can include at least one air inlet 117 that allows air to enter the article 100. During use, air can enter the article 100 through the at least one air inlet 117, thereby mixing with the vapor generated from the aerosol-generating component 130. The resulting aerosol can then be directed to one or more air outlets 115 via at least one air flow channel extending between the first outer housing component 110a and the inner housing component 120. For example, in this particular example, there are two air flow channels 180 that extend longitudinally along the length of the article 100 and cooperate with the air outlets 115 to form a flow path through the article 100.

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

[0198] It will be understood that the "inlet airflow direction" refers to the direction in which air is directed through at least one air inlet toward the aerosol-generating component. By establishing such an angle between the inlet airflow direction and the plane of the generally planar aerosol-generating component, the generally planar aerosol-generating component can direct air from the at least one air inlet in a specific direction through the article. In this manner, an article having a single airflow channel can be manufactured, and air from the at least one air inlet can be effectively directed toward the airflow channel. This configuration can also help reduce airflow turbulence within the at least one airflow channel compared to when the inlet airflow direction is generally perpendicular to the plane of the generally planar aerosol-generating component. Reducing turbulence within the at least one airflow channel can improve the quality of the generated aerosol.

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

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

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

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

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

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

[0205] The aerosol-generating component 130 may be at least partially disposed within the aerosol-forming chamber 190 .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0227] Features of this embodiment are shown schematically in Figures 5A-5D. As shown, the aerosol-generation component 130 includes at least two generally planar portions 130A', at least two of which lie in different planes.

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

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

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

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

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

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

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

[0235] Also disclosed is an article for use as part of a non-combustion aerosol delivery system, comprising an aerosol generating component 130 as defined herein and one or more of a reservoir 121 for aerosolizable material and an aerosol forming chamber 190.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0255] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or on the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

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

2. The article of claim 1 , wherein the aerosol-generating component is securely attached to the housing or a component within the housing.

3. The article of claim 1 or 2, wherein the aerosol generating component comprises one or more electrical connectors securely attached to one or more corresponding electrical contacts in the housing.

4. The article of any one of claims 1 to 3, wherein the aerosol-forming material transport component is spatially constrained by the housing or a component within the housing.

5. The article of any one of claims 1 to 3, wherein the aerosol-forming material transport component is not rigidly attached to the housing or a component within the housing.

6. The article of any one of claims 1 to 5, wherein the aerosol-generating component is substantially planar.

7. The article of any one of claims 1 to 6, wherein the aerosol generation component is curved.

8. The article of claim 7 , wherein the aerosol-generating component is curved about an axis of the aerosol-generating component.

9. 9. The article of claim 7 or 8, wherein the aerosol-generating material transport component is curved about the axis of the aerosol-generating component.

10. The article of any one of claims 1 to 9, comprising an aerosol formation chamber.

11. The article of claim 10 , wherein the aerosol generating component is at least partially disposed within the aerosol formation chamber.

12. The article of any one of claims 1 to 11, wherein the aerosol-generating component comprises one or more elongated apertures.

13. The article of any one of claims 1 to 12, wherein the aerosol-generating component is formed from an electrically conductive material.

14. The article of any one of claims 1 to 13, wherein the aerosol-generating component is formed from a porous material.

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

16. The article of any one of claims 1 to 15, wherein the housing defines at least one airflow channel.

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

Images