Aerosol delivery device and method for generating an aerosol

Abstract

An aerosol delivery device (202) is disclosed that comprises an aerosol generator (501), a receiving area for receiving an aerosol product, and a first layer (503) disposed between the aerosol generator (501) and the receiving area.

Description

[Technical field]

[0001] The present invention relates to an aerosol delivery device, an aerosol generation system, and a method for generating an aerosol. [Background technology]

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts have been made to provide an alternative to these articles by creating products that release compounds without burning. Examples of such products include so-called "heat-not-burn" products, which release compounds by heating a material without burning it, or tobacco heating devices or products. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0003] Aerosol delivery systems are known that cover the above mentioned devices or products. A typical system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. In many cases, the medium used must be replaced or changed to provide a different aerosol for inhalation. It is known to use an induction heating system as a heater to generate an aerosol from a suitable medium. An induction heating system generally consists of a magnetic field generating device for generating a fluctuating magnetic field, and a susceptor or heating material that can be heated by permeating the fluctuating magnetic field to heat a suitable medium.

[0004] A conventional aerosol delivery device includes a cylindrical heating chamber into which a rod-shaped consumable is inserted.

[0005] Next generation devices are contemplated in which consumables having shapes other than cylindrical are used, such as consumables comprising a planar substrate. The planar substrate may comprise a susceptor that is heated by penetration with a varying magnetic field. For example, the planar substrate may comprise a card base layer to which an aluminum foil layer is adhered. The aluminum foil layer may function as the susceptor. The aerosol generating material (i.e., gel) may be provided on the aluminum foil layer (susceptor). The planar substrate may be inserted into the aerosol delivery device and translated or rotated relative to the heating element. Summary of the Invention

[0006] According to one aspect, there is provided an aerosol delivery device comprising: an aerosol generator; a receiving area for receiving the aerosol product; a first layer disposed between the aerosol generator and the receiving area; An aerosol delivery device is provided comprising:

[0007] According to various embodiments, an aerosol delivery device is provided in which a first layer is provided between an aerosol generator (which may comprise one or more induction coils) and an aerosol product article that is inserted into the receiving area during use. The first layer may comprise a thermal insulating layer, or may comprise a glass or ceramic layer. According to another embodiment, the first layer may comprise polyetheretherketone (PEEK). It will thus be appreciated that, during use, the aerosol generator (such as one or more induction coils) does not directly contact the aerosol product article. Instead, a first insulating layer is provided between the aerosol generator (e.g., one or more induction coils) and the aerosol product article.

[0008] The first layer may have a low coefficient of linear expansion. For example, PEEK has a coefficient of linear expansion of about 50×10 -6 / °C, and glass and ceramics have a linear expansion coefficient of about 5 to 10 × 10 -6 / °C. As a result, the first layer can expand a negligible amount during use such that the distance between the one or more induction coils and a susceptor layer disposed within the aerosol product article remains substantially constant during operation, thereby improving the consistency of heating performance.

[0009] The first layer may comprise glass or ceramic, and the aerosol product article may be pressed against the first layer during use to generate an aerosol from an aerosol-generating material provided on the aerosol product article. The aerosol product article may comprise a substrate, a susceptor layer (e.g., aluminum foil), and a layer of aerosol-generating material.

[0010] It has been found that the heating performance of the susceptor layer can be dependent on the vertical separation distance between the susceptor layer and one or more induction coils.

[0011] According to various embodiments, a first layer is provided between the aerosol generator (i.e., one or more induction coils) and the aerosol product article, the first layer comprising a thermally insulating layer such as a glass or ceramic having a relatively low linear expansion coefficient, and the aerosol product article is pressed against the first layer to ensure that the separation distance between the susceptor layer of the aerosol product article and the one or more induction coils remains constant during use. As a result, uniform heating performance can be achieved.

[0012] Additionally, a first layer comprising a glass or ceramic is beneficial in that the glass or ceramic layer may have a relatively high resistance to thermal cycling.

[0013] Additionally, providing the first layer with a thermally insulating layer helps ensure that the aerosol product article inserted into the aerosol delivery device retains thermal energy and dissipates less thermal energy into the body of the aerosol delivery device during use. As a result, the aerosol delivery device can generate a first puff from the aerosol product article within a shortened period of time, which is particularly beneficial.

[0014] Optionally, the first layer comprises a thermal insulation layer.

[0015] Optionally, the first layer may comprise one or more layers of glass.

[0016] Optionally, the first layer may comprise one or more ceramic layers.

[0017] Optionally, the first layer may comprise a combination of one or more glass layers and one or more ceramic layers.

[0018] Optionally, the first layer may have a thermal conductivity of less than 0.01 W / mK, 0.01-0.05 W / mK, 0.05-0.1 W / mK, 0.1-0.5 W / mK, 0.5-1 W / mK, 1-5 W / mK, 5-10 W / mK, 10-20 W / mK, 20-30 W / mK, 30-40 W / mK, or 40-50 W / mK.

[0019] It is contemplated that the first layer may include a plastic material, such as polyetheretherketone (PEEK) or another material.

[0020] Optionally, the first layer has a flatness of ±1 μm, ±1-5 μm, ±5-10 μm, ±10-15 μm, ±15-20 μm or ±20-25 μm over a 10 mm by 10 mm area. Optionally, the first layer has a flatness tolerance of less than 1 μm, 1-5 μm, 5-10 μm, 10-15 μm, 15-20 μm or 20-25 μm. As the first layer may be in contact with an aerosol product article in use, and the aerosol product article may comprise a susceptor layer, it will be appreciated that having a first layer with a high level of flatness ensures that the distance between the susceptor layer and the one or more induction coils is substantially constant over a desired heating area.

[0021] Optionally, the lower surface of the first layer may include a plurality of castellations or regular protrusions. Other embodiments are contemplated in which the first (or upper) surface of the first layer may include a plurality of castellations or regular protrusions. The plurality of castellations or regular protrusions allows for the provision of additional air gaps between the aerosol product article and one or more induction coils or other portions of the aerosol delivery device.

[0022] It is contemplated that the castellations or regular protrusions on the second (or lower) surface and / or the first (or upper) surface of the first layer may all be the same size, or the castellations or regular protrusions on the second (or lower) surface and / or the first (or upper) surface of the first layer may have different sizes, widths or circumferences.

[0023] The castellations or regular projections may be hemispherical, elliptical, or polygonal in shape.

[0024] Optionally, the first (or upper) surface of the first layer may include one or more depressions.

[0025] Optionally, the first layer is magnetically permeable. For example, the first layer may be configured to transmit electromagnetic radiation emitted by the aerosol generator (i.e., the one or more induction coils) with a transmission efficiency of at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99%.

[0026] Optionally, the first layer has a melting point of 10×10 at a temperature range of 40 to 400° C. -6 The first layer may have a thermal expansion coefficient of less than 10 to 20 × 10 -6 / ℃, 20~30×10 -6 / ℃, 30~40×10 -6 / ℃, 40~50×10 -6 / ℃, 50-60×10 -6 / ℃, 60~70×10 -6 / ℃, 70~80×10 -6 / ℃, 80~90×10 -6 / ℃ or 90~100×10 -6 Other embodiments are contemplated that may have a coefficient of thermal expansion of 100 / °C.

[0027] Optionally, the first layer has a stiffness or Young's modulus greater than 50 GPa. For example, the first layer may have a Young's modulus in the range of 50-60 GPa, 60-70 GPa, 70-80 GPa, 80-90 GPa, 90-100 GPa, or greater than 100 GPa.

[0028] Optionally, the first layer may protrude from the surrounding housing, such that the aerosol product contacts the first layer but not the surrounding housing during use.

[0029] Optionally, the plurality of castellations or regular protrusions may form an air gap or air insulating layer.

[0030] Optionally, the air gap or air insulating layer is less than 50 μm, 50-100 μm, 100-150 μm, 150-200 μm, 200-250 μm, 250-300 μm, 300-350 μm, 350-400 μm or greater than 400 μm thick.

[0031] Optionally, the first layer may be less than 50 μm, 50-100 μm, 100-150 μm, 150-200 μm, 200-250 μm, 250-300 μm, 300-350 μm, 350-400 μm, 400-450 μm, 450-500 μm, 500-550 μm, 550-600 μm or greater than 600 μm thick.

[0032] Optionally, the aerosol generator comprises one or more inductive heating elements, the one or more inductive heating elements being at least partially embedded within the first layer.

[0033] Optionally, the aerosol generator may comprise one or more conductive tracks provided on and / or within the first layer. According to an embodiment, the one or more conductive tracks may form one or more elements of an inductive coil arrangement. The one or more conductive tracks may be printed, etched or deposited on the first layer.

[0034] Optionally, the first (or upper) surface of the first layer is convex, concave or planar. It is also contemplated that the second (or lower) surface of the first layer may be convex, concave or planar.

[0035] Optionally, the aerosol generator comprises one or more concave, convex or planar induction coils.

[0036] Optionally, the first layer is gas impermeable. Beneficially, any gas generated within the electronics housing, which may include one or more induction coils, is prevented by the first layer from escaping the electronics housing. Additionally, any gas that may be generated is prevented by the first layer from entering an aerosol chamber, which may be placed in contact with the aerosol product article, for example. For example, according to various embodiments, the aerosol chamber may be pressed into engagement with the aerosol product article, such that the separation distance between the susceptor layer and the one or more induction coils within the aerosol product article is tightly controlled, thereby enabling consistent heating of the susceptor layer.

[0037] According to another aspect, there is provided an aerosol generating system, comprising: an aerosol delivery device as described above; - an aerosol product; An aerosol generating system is provided, comprising:

[0038] Optionally, the aerosol product comprises: (i) a substantially circular, elliptical, or polyhedral substrate having one or more portions of aerosol-generating material disposed on a first surface of the substrate and / or one or more portions of aerosol-generating material disposed on a second surface of the substrate; (ii) a substantially planar substrate having one or more portions of an aerosol-generating material disposed on a first surface of the substrate and / or one or more portions of an aerosol-generating material disposed on a second surface of the substrate; or (iii) Aerosol products in the shape of a prism or cylinder Equipped with.

[0039] Optionally, the aerosol product comprises either an open consumable or a closed consumable.

[0040] According to another aspect, there is provided a method of generating an aerosol, comprising the steps of: providing an aerosol delivery device comprising an aerosol generator having a receiving area for receiving an aerosol product and a first layer between the aerosol generator and the receiving area; - inserting an aerosol product into a receiving area; A method is provided, comprising:

[0041] According to another aspect, there is provided an aerosol delivery device comprising: a receiving area for receiving the aerosol product; one or more first aerosol generators disposed on a first side of the receiving area; one or more second aerosol generators disposed on a second side of the receiving area; An aerosol delivery device is provided comprising:

[0042] Optionally, the aerosol delivery device further comprises a first thermal insulation layer disposed between the one or more first aerosol generators and the receiving area.

[0043] Optionally, the first thermal insulation layer has a plurality of castellations or regular protrusions that form air gaps or air insulation layers.

[0044] Optionally, the aerosol delivery device further comprises a second thermal insulation layer disposed between the one or more second aerosol generators and the receiving area.

[0045] Optionally, the second thermal insulation layer has a plurality of castellations or regular protrusions that form an air gap or air insulation layer.

[0046] According to another aspect, there is provided an aerosol delivery device comprising: one or more aerosol generators; a receiving area for receiving the aerosol product; a first thermal insulation layer disposed between the one or more aerosol generators and the receiving area, the first thermal insulation layer having a first side facing the receiving area and a second side opposite the receiving area, the first thermal insulation layer further comprising: (i) providing a plurality of castellations, regular projections or depressions on a first side of the first thermal insulation layer to form an air gap or air insulating layer between the first thermal insulation layer and the aerosol product article when the aerosol product article is disposed within the receiving area in use; and / or (ii) a first thermal insulation layer having a plurality of castellations, regular protrusions or depressions on a second side of the first thermal insulation layer to form an air gap or air insulation layer between the first thermal insulation layer and the one or more aerosol generators; An aerosol delivery device is provided comprising: [Brief description of the drawings]

[0047] Various embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1]1 is a schematic cross-sectional view of an aerosol delivery device and an aerosol product article, the aerosol delivery device including a plurality of induction coils and the aerosol product article including a plurality of portions of aerosol-generating material and corresponding susceptor portions. [Diagram 2] FIG. 1 illustrates an aerosol delivery device in combination with an aerosol product article, the aerosol product article comprising multiple portions of an aerosol generating material, the aerosol delivery device comprising a single induction heating element and a movement mechanism for rotating the aerosol product article relative to the single induction heating element. [Figure 3A] FIG. 2 is a plan view of the aerosol product. [Figure 3B] 1 is an end view of the aerosol product article showing multiple susceptors embedded in the aerosol product article. [Figure 3C] 1 is a side view of an aerosol product article showing multiple susceptors embedded in the aerosol product article. [Figure 4A] FIG. 1 is a perspective view of an aerosol delivery device having a mouthpiece in which a slidable fastener is used to secure an upper lid portion of the aerosol delivery device to a lower base portion. [Figure 4B] FIG. 13 is a perspective view of the slidable fastener removed. [Figure 4C] FIG. 2 is a perspective view of the aerosol delivery device with the lid open and an aerosol product inserted into the aerosol delivery device. [Diagram 5] FIG. 1 illustrates some components of an aerosol delivery device, in which a first (i.e., insulating) layer is provided above an induction coil, the first (i.e., insulating) layer being positioned so as to be in interfacial contact with the aerosol product during use. [Figure 6] FIG. 2 is an enlarged cross-sectional view of a portion of an aerosol delivery device showing a first (ie, insulating) layer disposed between the induction coil and the aerosol product. [Figure 7]FIG. 1 illustrates a configuration in which a first (i.e., insulating) layer is provided having a plurality of castellations provided on a second (or lower) surface of the first (i.e., insulating) layer that is positioned adjacent to one or more induction coils, the first (i.e., insulating) layer extending beyond the surrounding housing. [Figure 8A] 1 is a table showing the performance of the first (i.e., insulating) layer for different tests with various configurations during the calibration process and the time to reach the maximum desired set point temperature of 275° C. [Figure 8B] FIG. 13 shows how the temperature of the aluminum foil susceptor layer of the aerosol product changed over time with different test first (i.e., insulating) layers. [Figure 9A] 1 is a table showing the performance of the first (i.e., insulating) layer for different tests with various configurations and the time it takes for the surface of the foil susceptor layer of the aerosol product to reach the maximum desired set point temperature of 300° C. [Figure 9B] FIG. 13 shows how the temperature of the aluminum foil susceptor layer of the aerosol product changed over time with different test first (i.e., insulating) layers. [Figure 10A] 1 is a table showing the performance of the first (i.e., insulating) layer for different tests with various configurations and the time it takes for the surface of the layer of aerosol-generating material (gel) of the aerosol product article to reach a maximum desired set-point temperature of 300° C. [Figure 10B] FIG. 13 shows how the temperature of the surface of the layer of the aerosol product article changed over time using different test first (i.e., insulating) layers. [Figure 11]An exaggerated view of one configuration of a first (i.e., insulating) layer having a concave first (or upper) surface, where a curved aerosol product article is placed on the first (i.e., insulating) layer, such that when the aerosol product article is heated, the aerosol product article expands and a susceptor layer disposed within the aerosol product article assumes a planar profile, such that the separation distance between the susceptor layer and one or more induction coils is substantially constant over the desired heating area of ​​the aerosol product article. [Figure 12] A diagram showing a configuration in which a concave first (i.e., insulating) layer is provided on a concave-shaped inductor coil and an aerosol product having a similar concave profile is placed on the first (i.e., insulating) layer. [Figure 13A] FIG. 1 illustrates a construction in which a planar inductor coil is bonded to the second (or lower) surface of a first (ie, insulating) layer. [Figure 13B] FIG. 1 illustrates a construction in which a planar inductor coil is embedded within a first (ie, insulating) layer. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0048] Aspects and features of certain examples and embodiments are discussed or described herein. Some aspects and features of certain examples and embodiments may be implemented in a conventional manner and, for the sake of brevity, will not be discussed or described in detail. Thus, it will be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented in accordance with conventional techniques for implementing such aspects and features.

[0049] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0050] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system. In some embodiments, 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. In some embodiments, 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.

[0051] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0052] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0053] In some embodiments, the present disclosure relates to consumables that include aerosol generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0054] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material in proximity to the heat generating power source.

[0055] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0056] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material delivery components, aerosol generators, aerosol generating areas, housings, packaging materials, filters, mouthpieces, and / or aerosol modifiers.

[0057] An aerosol-generating material is, for example, a material that can generate an aerosol when heated, irradiated, or energized in any other manner. The aerosol-generating material may be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or fragrances.

[0058] The aerosol-generating material may include a binder and an aerosol-forming agent. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0059] The aerosol-generating film may include or be a sheet that can optionally be chopped to form chopped sheets.

[0060] The aerosol-generating materials may include one or more active agents and / or flavorants, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0061] The aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to provide thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, pressure increase, or electrostatic energy.

[0062] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which are intended to be consumed during use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that emits heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0063] The susceptor is a heating material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. An aerosol delivery device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0064] The non-combustion aerosol delivery system may comprise a modular assembly including both a reusable aerosol delivery device and a replaceable aerosol product article. In some implementations, the non-combustion aerosol delivery device may comprise a power source and a controller (or control circuitry). The power source may include a power source, such as, for example, a battery or a rechargeable battery. In some implementations, the non-combustion aerosol delivery device may also comprise an aerosol generating component. However, in other implementations, the aerosol product article may comprise, in part or in whole, the aerosol generating component.

[0065] Induction heating is a process in which an electrically conductive object, called a susceptor, is heated by penetrating the object with a varying magnetic field. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electric current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are appropriately positioned relative to one another such that the resulting varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of electric current, and when such eddy currents are generated within the object, their flow against the electrical resistance of the object heats the object. This process is called Joule heating, Ohmic heating, or resistive heating.

[0066] Magnetic hysteresis heating is the process by which an object made of a magnetic material is heated by permeating the object with a varying magnetic field. The magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field permeates such a material, the magnetic dipoles align with the magnetic field. Thus, when a varying magnetic field, for example an alternating magnetic field as produced by an electromagnet, permeates a magnetic material, the orientation of the magnetic dipoles changes with the applied varying magnetic field. Such magnetic dipole reorientation causes the generation of heat within the magnetic material.

[0067] When an object is both conductive and magnetic, the penetration of a varying magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can strengthen the magnetic field, which can enhance Joule heating.

[0068] Various embodiments will now be described in more detail.

[0069] 1 shows a cross-sectional view of a schematic diagram of an aerosol delivery system according to one configuration. Aerosol delivery device 202 is shown as including an outer housing 221, a power source 222, control circuitry 223, one or more inductive heating elements such as induction coils 224a, a receiving area or aerosol formation chamber 225, a mouth end 226, an air inlet 227, an air outlet 228, a touch-sensitive panel 229, an inhalation sensor 230, and an end-of-use indicator 231.

[0070] According to various embodiments described in more detail below, an aerosol delivery device is disclosed that includes an aerosol generator (which may include one or more inductive coils 224a), a receiving area for receiving an aerosol product, and a first layer disposed between the aerosol generator and the receiving area. For clarity, the barrier layer is not shown or described in connection with Figures 1-4, but is illustrated below in connection with Figures 5-7 and 11-13.

[0071] In the configuration, the one or more induction heating elements 224a may comprise one or more of: (i) a flat spiral coil, where the spiral coil may include a circular or oval spiral, a square or rectangular spiral, a trapezoidal spiral, or a triangular spiral; (ii) a multi-layer induction configuration in which subsequent full or partial turns of the coil are provided on adjacent layers, optionally with a first layer spaced apart from a second layer in a first direction and a third layer spaced apart from the second layer in an opposite direction and within or near the first layer, such that the multi-layer induction configuration forms a staggered structure; or (iii) a three-dimensional inductor coil, such as a regular helical or conical shaped inductor coil, optionally with a variable helical pitch.

[0072] The aerosol delivery device 202 may include a lid portion, a base portion, and a fixing portion.

[0073] The outer housing 221 may be formed from any suitable material, for example a plastic material. The outer housing 221 may be configured such that the power source 222, the control circuitry 223, the one or more induction coils 224a, the receiving area 225, and the inhalation sensor 230 are disposed within the outer housing 221. The outer housing 221 also defines an air inlet 227 and an air outlet 228. The touch sensitive panel 229 and the end of use indicator 231 may be disposed on the exterior of the outer housing 221.

[0074] The outer housing 221 further includes a mouth end 226. The outer housing 221 and the mouth end 226 may be formed as a single component (i.e., the mouth end 226 may form a part of the outer housing 221). The mouth end 226 is defined as the area of ​​the outer housing 221 that includes the air outlet 228 and is shaped such that a user may comfortably place their lips around the mouth end 226 to engage the air outlet 228.

[0075] The thickness of the outer housing 221 may decrease towards the air outlet 228 to provide a relatively thin portion of the aerosol delivery device 202 that may be more easily accepted by the user's lips.

[0076] The power source 222 may be configured to provide operating power to the aerosol delivery device 202. The power source 222 may comprise any suitable power source, such as a battery. For example, the power source 222 may include a rechargeable battery, such as a lithium ion battery ("LIB"). The power source 222 may be removable or may form an integrated part of the aerosol delivery device 202. The power source 222 may be recharged by connecting the aerosol delivery device 202 to an external power source (such as a mains power source) via an associated connection port, such as a USB port (not shown), or via a suitable wireless receiver (not shown).

[0077] Control circuitry 223 may be suitably configured or programmed to control the operation of aerosol delivery device 202 to provide a particular operational function of aerosol delivery device 202. Control circuitry 223 may be considered to logically comprise various subunits or circuit elements associated with different aspects of the operation of aerosol delivery device 202. For example, control circuitry 223 may comprise a logical subunit for controlling the recharging of power source 222.

[0078] The aerosol delivery device 202 may further comprise a receiving area 225 configured to receive the aerosol product article 204. The receiving area 225 may be of a size suitable to removably receive the aerosol product article 204 therein. The aerosol product article 204 may include a carrier component or substrate (e.g., a card) 242, one or more susceptors or susceptor layers, and an aerosol-generating material 244 disposed on the one or more susceptors or susceptor layers. According to one construction, a single susceptor layer may be provided, the single susceptor layer comprising an aluminum or metal foil layer.

[0079] The aerosol delivery device 202 may include a lid and a base configured to engage with one another. A securing mechanism may be provided to secure the lid to the base. Various configurations of the lid and base are contemplated. The aerosol delivery device 202 may include a hinged door or removable portion of the outer housing 221 that allows access to the receiving area 225 so that a user may insert and / or remove the aerosol product article 204 into / from the receiving area 225. The hinged door or removable portion of the outer housing 221 may also function to retain the aerosol product article 204 within the receiving area 225 when closed.

[0080] When the aerosol product item 204 is used up or the user simply desires to switch to a different aerosol product item 204, the aerosol product item 204 may be removed from the aerosol delivery device 202 and a replacement aerosol product item 204 may be placed in its place within the receiving area 225.

[0081] The aerosol delivery device 202 may include a permanent opening in communication with the receiving area 225 through which the aerosol product article 204 can be inserted into the receiving area 225. In such implementations, a retention mechanism may be provided for retaining the aerosol product article 204 within the receiving area 225 of the aerosol delivery device 202.

[0082] The retention mechanism may comprise a locking mechanism configured to engage the lid with the base to hold the aerosol product article 204 in place during use to prevent relative movement of the aerosol product article 204. For example, the lid and base may be configured to hold the aerosol product article 204 in a position between the lid and base.

[0083] 2 shows a schematic diagram of a portion of an aerosol delivery device 202 according to one configuration. The aerosol delivery device 202 is shown with an aerosol product article 204 that includes an aerosol-generating material disposed within the aerosol delivery device 202. The combination of the aerosol delivery device 202 and the aerosol product article 204 together form an aerosol delivery system.

[0084] The aerosol product article 204 has a first (or upper) surface 112 on which the aerosol-generating material 244 may be disposed. The aerosol product article 204 may comprise a carrier layer 242 (sometimes referred to herein as a carrier or substrate support layer) and a susceptor layer on which the aerosol-generating material 244 may be disposed. The aerosol-generating material 244 may be disposed as multiple doses of the aerosol-generating material. The aerosol product article 204 has a second (or lower) surface 116 opposite the first surface 112. The first surface 112 and / or the second surface 116 may be smooth or rough.

[0085] The aerosol-delivery device 202 may include one or more inductive heating elements 224a positioned to face the second surface 116 of the aerosol product article 204. The one or more inductive heating elements 224a may be configured to transfer energy from a power source, such as a battery (not shown), to the aerosol-generating material 244 to generate an aerosol from the aerosol-generating material 244.

[0086] The aerosol delivery device 202 in one configuration may have a moving mechanism 130 configured to move a particular portion (or, in some cases, a dose) of the aerosol product article 204, and in particular the aerosol-generating material 244. That portion of the aerosol-generating material 244 may be rotated relative to one or more induction heating elements or induction coils 224a, in this case such that that portion of the aerosol-generating material 244 is individually presented to the induction heating element or induction coil 224a. In the configuration shown in FIG. 2, the induction heating element 224a may comprise an induction coil, and the aerosol product article 204 includes a layer that functions as a susceptor.

[0087] The aerosol delivery device 202 may be configured such that at least one dose of the aerosol generating material 244 is rotated about the axis A at an angle θ relative to the second surface 116. The control circuitry 223 may be configured to operate both the induction heating element or induction coil 224a and the movement mechanism 130 such that the aerosol product article 204 is rotated to align the individual portions of the aerosol generating material 244 proximate to the induction heating element or induction coil 224a. The aerosol product article 204 may be substantially flat or planar. The carrier layer 242 of the aerosol product article 204 may be formed partially or entirely from paper or card.

[0088] 2 includes five doses (or portions) of aerosol-generating material 244. In other examples, the aerosol product article 204 may have more or fewer doses of aerosol-generating material 244. In some examples, the aerosol product article 204 may have doses of aerosol-generating material 244 arranged in individual doses, as shown in FIG.

[0089] In other examples, the doses may be in the form of a disk, which may be continuous or discontinuous around the circumference of the aerosol product article 204. In yet other examples, the doses may be in the form of annulus, ring, or any other shape. The aerosol product article 204 may or may not have a rotationally symmetric distribution of doses on the first surface 112 about the axis A. A symmetric distribution of doses allows equivalently positioned doses (within a rotationally symmetric distribution) to receive equivalent heating profiles from the induction heating element or induction coil 224a upon rotation about the axis A, if desired.

[0090] The aerosol product article 204 in this example includes an aerosol-generating material 244 disposed on a susceptor layer of the aerosol product article 204. However, in other implementations, the aerosol product article 204 may be formed solely from the aerosol-generating material 244. That is, in some implementations, the aerosol product article 204 may consist entirely of the aerosol-generating material 244. In this example, one or more susceptor elements may be provided as part of the aerosol generating device 204.

[0091] The aerosol product article 204 may have a layered structure and may be formed from multiple materials. In one example, the aerosol product article 204 may have a layer formed from at least one of a thermally conductive material, a dielectric material, a permeable material, or an impermeable material.

[0092] In some implementations, the carrier layer 242 or substrate may be or include a metal element that is configured to be heated by a varying magnetic field and thus may function as a susceptor layer. In such implementations, the inductive heating element 224a may include one or more inductive coils 224a that, when energized, cause heating in the metal element of the aerosol product article 204. The degree of heating may be affected by the distance between the metal element or susceptor layer and the inductive coils 224a.

[0093] The arrangement shown in Figure 2 operates by allocating (or moving) multiple doses of aerosol-generating material 244 to an induction heating element or induction coil 224a. While this arrangement in Figure 2 may slightly increase the complexity of the moving mechanism 130 for effecting the movement to the aerosol product article 204, it provides an advantage by allowing the aerosol delivery device 204 to include a single induction heating element 224a that is used to heat multiple portions of the aerosol-generating material 244. It will be appreciated that a single heating element 224a requires a single control mechanism (such as control circuit 223) while multiple heaters may each require a separate control mechanism. Thus, this arrangement may reduce the cost and control complexity associated with the operation and control of the induction heating element 224a.

[0094] The shape of the aerosol delivery device 202 may be cigarette-shaped (one dimension longer than the other two dimensions) or may be some other shape. In one example, the aerosol delivery device 202 may have a shape in which two dimensions are longer than one other dimension, such as a compact disc player. Alternatively, the shape may be any shape that can adequately accommodate the aerosol product article 204, the one or more inductive heating elements or induction coils 224a, and the movement mechanism 130.

[0095] The aerosol product article 204 may include a carrier component 242, which may be formed from a card. The carrier component 242 may form the majority of the aerosol product article 204 and may serve as a base for one or more susceptors or susceptor layers on which the aerosol-generating material 244 is provided or deposited. The carrier component 242 may be approximately rectangular in shape. The carrier component 242 may have a length of 30-80 mm, a width of 7-25 mm, and a thickness of 0.2 mm. However, it should be understood that other configurations are contemplated in which the carrier component 242 may have different dimensions as needed.

[0096] The aerosol product article 204 may comprise multiple individual portions of the aerosol-generating material 244 disposed on a surface of the carrier component 242. According to one configuration, the aerosol product article 204 may comprise 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 or more than 15 individual portions of the aerosol-generating material 244.

[0097] The individual portions of aerosol-generating material 244 may be arranged in an n by m array. However, it should be understood that in other implementations a greater or lesser number of individual portions may be provided and / or the portions may be arranged in a different format of the array (e.g., a 1 by 6 array). Other configurations are contemplated in which the aerosol product article 204 comprises a disk and the separate portions of aerosol-generating material 244 are provided within separate segments of the disk.

[0098] The aerosol-generating material 244 may be disposed at individual, separate locations on a single surface of the component carrier 242. Although the individual portions of the aerosol-generating material 244 are shown as having a circular footprint, it should be understood that the individual portions of the aerosol-generating material 244 may take on any other footprint, such as a square, trapezoid, or rectangular, as desired.

[0099] The individual portions of aerosol-generating material 244 may be disposed separately from one another such that each of the individual portions may be individually or selectively energized (eg, heated) to generate an aerosol.

[0100] The aerosol product article 204 may comprise multiple portions of aerosol-generating material 244 that are all formed from the same aerosol-generating material. Alternatively, the aerosol product article 204 may comprise multiple portions of aerosol-generating material 244, where at least two portions are formed from different aerosol-generating materials.

[0101] The one or more induction heating elements or induction coils 224a may be arranged such that a surface of the one or more induction heating elements or induction coils 224a forms part of a surface of the receiving area 225. That is, an outer or first (upper) surface of the one or more induction heating elements or induction coils 224a is flush with the inner surface of the receiving area 225.

[0102] The one or more inductive heating elements or coils 224a may be configured such that when the aerosol product article 204 is received in the receiving area 225, each inductive heating element or coil 224a aligns with a corresponding individual portion of the aerosol-generating material 244. For example, if six inductive heating elements or coils 224a are arranged in a 2×3 array, the aerosol product article 204 may comprise a 2×3 array of six individual portions of the aerosol-generating material 244. However, as discussed above, the number of inductive heating elements or coils 224a may vary in different implementations. For example, according to various configurations, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 individual inductive heating elements or coils 224a may be provided.

[0103] Each of the inductive heating elements or coils 224a can be individually actuated to heat a corresponding portion of the aerosol-generating material 244. Although the inductive heating elements or coils 224a are shown flush with the inner surface of the receiving area 225, in other implementations the inductive heating elements or coils 224a may protrude into the receiving area 225.

[0104] The receiving area 225 may comprise components that apply a force to a surface of the aerosol product article 204 to press the aerosol product article 204 against a surface of the aerosol delivery device 202 to prevent relative motion of the aerosol product article 204. As will be appreciated, the lid of the aerosol delivery device 202 may be configured to engage with the base, for example via a securing mechanism, such that the lid and / or base comprise components that apply a force to a surface of the aerosol product article 204 to secure the aerosol product article 204 against relative motion.

[0105] In configurations in which the aerosol product article 204 is configured to move in a specified or desired direction relative to one or more induction heater elements or induction coils 224a, the securing mechanism may be configured to engage the lid with the base to hold the aerosol product article 204 in a fixed position to prevent relative movement of the aerosol product article 204, thereby preventing relative movement in any direction other than the specified or desired direction.

[0106] For example, in an arrangement in which the aerosol product article 204 is configured to rotate about an axis of rotation relative to one or more induction heater elements or induction coils 224a to present a fresh area of ​​aerosol-generating material on the aerosol product article 204 to the one or more induction heater elements or induction coils 224a, the securing mechanism may be configured to engage the lid with the base to prevent relative movement of the aerosol product article 204 in directions other than rotation about the axis of rotation, while still allowing the aerosol product article 204 to be rotated relative to the one or more induction heater elements or induction coils 224a.

[0107] One or more induction coils 224a may be provided adjacent the receiving area 225 and may comprise substantially flat coils arranged such that the axis of rotation about which a given coil is wound extends within the receiving area 225 and is approximately perpendicular to the plane of the carrier component 242 of the aerosol product article 204.

[0108] The control circuitry 223 may include a mechanism for generating an alternating current through any one or more of the induction coils 224a. The alternating current generates an alternating magnetic field that heats the corresponding portion of the susceptor or susceptor layer. The heat generated by the susceptor or portion of the susceptor layer is transferred accordingly to the portion of the aerosol-generating material 244.

[0109] Various configurations have been described in which one or more susceptors are provided as part of the aerosol product article 204. However, other configurations in which one or more susceptors are disposed within or as part of the aerosol delivery device 202 are also contemplated. For example, one or more susceptors may be provided above one or more induction coils 224a, or may be positioned such that one or more susceptors contact a second (or lower) surface of the carrier component 242.

[0110] An aerosol product article 204 for use with the aerosol delivery device 202 may comprise a carrier component 242, one or more susceptor elements 224b, and one or more portions of aerosol-generating material 244a-f, as shown and described in more detail with reference to Figures 3A-3C.

[0111] FIG. 3A shows a top view of an aerosol product 204 of one configuration, FIG. 3B shows an end view of an aerosol product 204 of one configuration along its longitudinal (length) axis, and FIG. 3C shows a side view of an aerosol product 204 of one configuration along its width axis.

[0112] One or more susceptor elements 224b may be formed from aluminum foil, although it should be understood that in other implementations, other metals and / or conductive materials may be used. As seen in FIG. 3C, the carrier component 242 may include several susceptor elements 224b that correspond in size and position to the individual portions of aerosol-generating material 244a-f disposed on a surface of the carrier component 242. That is, the susceptor elements 224b may have similar widths and lengths as the individual portions of aerosol-generating material 244a-f.

[0113] The susceptor element 224b is shown embedded in the carrier component 242. However, in other configurations, the susceptor element 224b may be placed or disposed on a surface of the carrier component 242. According to another implementation, the susceptor may be provided as a single layer that substantially covers the carrier component 244. According to one configuration, the aerosol product article 204 may comprise a substrate or support layer, a single layer of aluminum foil that functions as a susceptor, and one or more regions of aerosol-generating material 244 deposited on the aluminum foil susceptor layer.

[0114] According to one configuration, an array of induction heating coils 224a may be provided to energize discrete portions of the aerosol-generating material 244. However, according to other configurations, a single induction coil 224a may be provided and the aerosol product article 204 may be configured to move relative to the single induction coil 224a. Thus, there may be fewer induction coils 224a than discrete portions of the aerosol-generating material 244 provided on the carrier component 242 of the aerosol product article 204.

[0115] Alternatively, a single induction coil 224a may be provided and the aerosol product article 204 may be rotated relative to the single induction coil 224a. For example, a movable induction heating element may be provided within the receiving area 225 such that the induction heating element may move relative to the receiving area 225. In this manner, the movable induction heating element may be translated (e.g., across the width and length of the carrier component 242) such that the induction heating element 224a may be aligned with each one of the discrete portions of the aerosol-generating material 244.

[0116] While implementations are described above in which individual, spatially discrete portions of aerosol-generating material 244 are deposited on the carrier component 242, it should be understood that in other implementations, the aerosol-generating material 244 may not be provided as individual, spatially discrete portions, but instead may be provided as a continuous sheet, film, or layer of aerosol-generating material 244. In these implementations, certain regions of the sheet of aerosol-generating material 244 may be selectively heated to generate aerosols in much the same manner as described above.

[0117] While it has been described above that the heating element 224a is configured to provide heat to the aerosol-generating material 244 (or a portion thereof) at an operating temperature at which an aerosol is generated from the portion of the aerosol-generating material 244, in some implementations, the one or more inductive heating elements or induction coils 224a and associated susceptor elements may be configured to preheat a portion of the aerosol-generating material to a preheat temperature (lower than the operating temperature) at which a smaller amount of aerosol or no aerosol is generated when the portion is heated at the preheat temperature. Notably, in some implementations, the control circuitry 223 may be configured to provide power or energy prior to the start of a first predetermined period, i.e., prior to receiving a signal indicating the user's intent to inhale the aerosol.

[0118] Each of the one or more induction heating elements or induction coils 224a may provide the same heating profile to the respective aerosol generation region, although it will be appreciated that one or more of the induction heating elements or induction coils 224a may alternatively be configured to provide different heating profiles to different respective aerosol generation regions.

[0119] The aerosol delivery device 202 may include a rotation device configured to rotate the aerosol product article 204 about an axis of rotation. The rotation device may be configured to rotate the aerosol product article 204 relative to the one or more induction coils 224a such that one or more fresh aerosol-generating regions of the aerosol product article 204 are moved into proximity with the one or more induction coils 224a. The locking mechanism may be configured to allow the aerosol product article 204 to be rotated relative to the one or more induction coils 224a while preventing relative movement of the aerosol product article 204 in a direction other than rotation about the axis of rotation, such as the z-direction as shown in FIG. 1.

[0120] In some configurations, the aerosol product article 204 may include one or more tracks, and the lid and / or base may be configured to apply a force along the one or more tracks to allow the aerosol product article 204 to rotate while preventing relative motion of the aerosol product article 204 in directions other than rotation about the axis of rotation. In some configurations, the one or more tracks may include an area of ​​the aerosol product article 204 that does not include aerosol-generating material. In some configurations, the one or more tracks may include an area of ​​the aerosol product article 204 that includes metal foil.

[0121] The lid may include a plenum and a mouthpiece. In some configurations, the mouthpiece and plenum may be integral with the lid. It will be appreciated that an integrated mouthpiece and lid ensures even compression on the aerosol product article 204. It is also contemplated that the plenum may be removable.

[0122] 4A shows an aerosol delivery device in one configuration, comprising a lid 1006 and a base 1008. A fastening mechanism 1010 may be provided comprising a fastener, such as a slidable fastener, configured to clamp the lid 1006 to the base 1008 so as to engage the lid 1006 of the aerosol delivery device 202 with the base 1008. Alternatively or additionally, the fastening mechanism may comprise a rotatable fastener. The lid 1006 may pivot about a hinge mechanism 1034.

[0123] The lid 1006 and / or base 1008 may include one or more walls configured to form an aerosol chamber or an aerosol formation chamber when the lid 1006 engages the base 1008. The lid 1006 and / or base 1008 may apply pressure uniformly to the substantially planar aerosol product article via the one or more walls to prevent relative movement of the aerosol product article.

[0124] FIG. 4B shows the securing mechanism 1010 removed, and FIG. 4C shows the lid 1006 in an open position with the aerosol product 204 inserted or within the aerosol delivery device 202.

[0125] 5 illustrates a portion of an aerosol delivery device 202 in one configuration, including a component 520 that may include an aerosol chamber and a mouthpiece 226. The aerosol chamber may be configured to receive aerosol generated from a portion of the aerosol product 204 inserted into the aerosol delivery device 202. The aerosol received within the aerosol chamber may then be transmitted forward to the mouthpiece 226, such that the aerosol may be inhaled by a user.

[0126] As explained above, a portion of component 520 (particularly the aerosol chamber) may be configured to contact the aerosol product article 204 when it is desired to generate an aerosol from the aerosol product article 204. A portion of component 520 may be forced into engagement with the aerosol product article 204, thereby securing the aerosol product article 204 against the first (i.e., insulating) layer 503.

[0127] According to one configuration, the aerosol production article 204 may be configured to contact the first (i.e., insulating) layer 503 when it is desired to generate an aerosol. The first (i.e., insulating) layer 503 may be substantially transparent to the magnetic field emitted by the one or more induction coils 501. For example, the first (i.e., insulating) layer 503 may be configured to transmit electromagnetic radiation emitted by the aerosol generator (i.e., the one or more induction coils 501) with a transmission efficiency of at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99%.

[0128] The aerosol product article 204 is shown inserted into a portion of the aerosol delivery device 202. The aerosol product article 204 may comprise a base support layer 504 (which may comprise a card), a susceptor layer 506 (which may comprise aluminum foil), and a layer of aerosol-generating material 507 (which may comprise a film of gel).

[0129] A consumable bed 500 is shown with a PCB inductor coil 501 disposed within the consumable bed 500. The inductor coil 501 is adhered to the backside of a first (i.e., insulating) layer 503 by an adhesive layer 502. The first (i.e., insulating) layer 503 is fixed to the consumable bed 500 and cannot rotate.

[0130] As will be appreciated, according to various configurations, the component 520 may be removed from contact with the aerosol product article 204, thereby allowing the aerosol product article 204 to rotate relative to the induction coil 501.

[0131] 5, induction coil 501 may be configured to heat region 505 of susceptor 506, thereby heating a corresponding region of aerosol-generating material provided in layer 507 containing aerosol-generating material. As a result, a dose of aerosol may be emitted from aerosol-generating layer 507, and the resulting aerosol may then be captured by an aerosol chamber forming part of component 520. The aerosol may then be transmitted onward from the aerosol chamber to mouthpiece 226.

[0132] Once the dose of aerosol has been released, the aerosol product article 204 may then be rotated, such that a fresh portion of aerosol generating material is positioned above the induction coil 501. For example, the aerosol product article 204 may be rotated 6, 7, 8, 9, 10, 11, 12 or more than 12 times during a use session. To rotate the aerosol product article 204 relative to the induction coil 501, the component 520 containing the aerosol chamber may be removed from contact with the aerosol product article 204.

[0133] According to one configuration, an aerosol delivery device 202 is disclosed that includes an aerosol generator. The aerosol generator may include, for example, one or more inductive coils 501 or inductive heating elements.

[0134] 6 shows an enlarged cross-sectional view of a portion of the aerosol delivery device 202 in one configuration with the aerosol product article 204 inserted into the aerosol delivery device 202. The aerosol product article 204 may be forced into contact with a barrier layer 503 disposed between the induction coil 501 and the aerosol product article 204. The first (i.e., insulating) layer 503 may comprise a thermal insulation layer including a glass, ceramic or plastic layer. The barrier layer may be optically transparent and may have a thermal conductivity of less than 0.01 W / mK. 0.01-0.05 W / mK, 0.05-0.1 W / mK, 0.1-0.5 W / mK, 0.5-1 W / mK, 1-5 W / mK, 5-10 W / mK, 10-20 W / mK, 20-30 W / mK, 30-40 W / mK and 40-50 W / mK. It is also contemplated that the barrier layer 503 may comprise a plastic material such as polyetheretherketone (PEEK).

[0135] 6, the first (i.e., insulating) layer 503 may be integral with the consumable bed 500. Alternatively, the first (i.e., insulating) layer 503 may be secured within or to the consumable bed 500.

[0136] The first (i.e., insulating) layer 503 may have a flatness of ±1 μm, ±1-5 μm, ±5-10 μm, ±10-15 μm, ±15-20 μm, or ±20-25 μm over a 10 mm by 10 mm area. According to various constructions, the first (i.e., insulating) layer 503 may have a flatness tolerance of less than 1 μm, 1-5 μm, 5-10 μm, 10-15 μm, 15-20 μm, or 20-25 μm. It will be appreciated that since the first (i.e., insulating) layer 503 may be in contact with the aerosol product article 204 in use, which may comprise a susceptor layer 506, ensuring that the first (i.e., insulating) layer 503 has a high level of flatness ensures that the distance between the susceptor layer 506 and the one or more induction coils 501 is substantially constant across the desired heating area. As a result, a uniform heating configuration is provided.

[0137] FIG. 7 illustrates an arrangement in which a barrier layer 503 comprising a plurality of castellations is provided on a second (or lower) surface of a first (i.e., insulating) layer 503. The first (i.e., insulating) layer 503 is disposed adjacent to one or more induction coils 501 to provide thermal or thermal insulation to the one or more induction coils 501 and, more generally, to insulate the aerosol product article from the body portion of the aerosol delivery device 202. The castellations may be provided on the second (or lower) surface of the first (i.e., insulating) layer 503 and an air gap may be provided by or around the castellations. The castellations may have a depth of less than 100 μm, 100-200 μm, 200-300 μm or 300-400 μm. The castellations provide improved thermal insulation, resulting in a greater amount of thermal energy being retained by the susceptor of the aerosol product article. As a result, the aerosol product article can be heated to a desired set point temperature more quickly, which is particularly beneficial as it allows a user to generate a puff of aerosol on demand within a time period of about 1 second. According to other configurations, the aerosol product article may be heated to a desired set point temperature within a time period of less than 1 second, 1-2 seconds, 2-3 seconds, or 3-4 seconds.

[0138] According to various configurations, the second (or lower) surface of the first (i.e., insulating) layer 503 may comprise a plurality of castellations or regular protrusions. However, other configurations are contemplated in which the first (i.e., insulating) layer 503's first (upper) surface may additionally or alternatively comprise a plurality of castellations or regular protrusions. The plurality of castellations or regular protrusions allows for the provision of air gaps that provide additional thermal insulation or thermal insulation in addition to the first (i.e., insulating) layer 503 itself. It is contemplated that the castellations or regular protrusions provided on the second (or lower) surface and / or the first (or upper) surface of the first (i.e., insulating) layer 503 may all be the same size and / or have the same profile. Alternatively, the castellations or regular protrusions provided on the second (or lower) surface and / or the first (or upper) surface of the first (i.e., insulating) layer 503 may have different sizes, widths, circumferences or profiles. The castellations or regular projections may be hemispherical, elliptical, or polygonal in shape. The castellations or projections may be provided in a regular array. Alternatively, the castellations or projections may be provided in an irregular or non-repeating manner.

[0139] 7, the first (i.e., insulating) layer 503 may be positioned to protrude beyond the surrounding housing 550, such that the aerosol product article, when inserted into the aerosol delivery device 202, may be positioned to contact the first (i.e., insulating) layer 503 rather than the surrounding housing 550. For example, the aerosol product article may be substantially rigid such that when the aerosol product article contacts the first (i.e., insulating) layer 503, the aerosol product article contacts the first (i.e., insulating) layer 503 but not the surrounding housing 550. As a result, the insulation of the aerosol product article is improved. It is contemplated that the aerosol product article may have a stiffness or Young's modulus of less than 10 GPa, 10-20 GPa, 20-30 GPa, 30-40 GPa, 40-50 GPa, 50-60 GPa, 60-70 GPa, 70-80 GPa, 80-90 GPa, 90-100 GPa, or greater than 100 GPa, such that the aerosol product article only contacts the first (i.e., insulating) layer 503 and not the housing immediately adjacent to the first (i.e., insulating) layer 503. It will be appreciated that the aerosol product article may additionally contact an aerosol chamber provided, for example, in the lid of the aerosol delivery device.

[0140] FIG. 8A shows a table illustrating the performance of different test first (i.e., insulating) layers and the time to reach the maximum desired set point temperature of 275° C. A variety of different first (i.e., insulating) layers were tested, including white ceramic (W), black ceramic with yttrium oxide (B), two different types of glass, and two different thicknesses of polyetheretherketone (PEEK). FIG. 8B shows how the temperature of the aluminum foil susceptor layer of the aerosol product changed as a function of time using the different test first (i.e., insulating) layers during the calibration routine.

[0141] The maximum temperature of the aluminum foil susceptor layer (TC Max ), the time to reach the maximum temperature, and the determined temperature gradient are shown.

[0142] The determined temperature gradient is related to the determined resonant frequency of the resonant circuit including the susceptor layer. The determined temperature gradient is a measure of the change in resonant waveform period per degree Celsius. According to various configurations, the temperature of the susceptor layer disposed within the aerosol product article may be determined by measuring the damped resonant frequency of a series resistor-inductor-capacitor network. The capacitance is fixed (e.g., with PCB components), the resistance is due in part to the resistivity of the susceptor foil, and the inductance is mostly fixed by the inductor coil.

[0143] It will be appreciated that as the temperature of the susceptor increases, both the foil resistivity and z-height increase, resulting in a decrease in the measured resonant frequency. The temperature gradient is a measure of the change in resonant waveform period per degree Celsius (time period is 1 / frequency). For example, if the resonant frequency at a temperature of 100°C is determined to be 2.1980 MHz, then the time period = 1 / 2.198 MHz = 454.96 ns. If the resonant frequency at a temperature 1°C higher, i.e., 101°C, is 2.1975 MHz, then the temperature gradient is 95 ps / °C, i.e., 1 / (454.96 ns + 95 ps) = 2.1975 MHz.

[0144] The time vs. temperature or resonant frequency vs. temperature response is non-linear, therefore determining the calculated temperature by measuring the resonant frequency is most accurate at the two temperatures used for calibration, which may be the ambient temperature (e.g., 22°C) and a high temperature calibration point, e.g., 275°C.

[0145] According to one construction, the first (i.e., insulating) layer may include a ceramic, such as yttrium (II) oxide (YO), which may have a dark brown color. Alternatively, the first (i.e., insulating) layer may be formed of an optically transparent ceramic, such as yttrium (III) oxide (YO). According to another construction, the first (i.e., insulating) layer may include a glass, such as an alkaline earth aluminosilicate glass. The glass may be free of alkali oxides and may contain 15-25% Al2O3, 52-60% SiO2, and about 15% alkaline earths. The first (i.e., insulating) layer may have a thickness of less than 50 μm, 50-100 μm, 100-150 μm, 150-200 μm, 200-250 μm, 250-300 μm, 300-350 μm, 350-400 μm, 400-450 μm, 450-500 μm, 500-550 μm, 550-600 μm or greater than 600 μm.

[0146] The temperature gradient may be considered an indication of how rapidly the susceptor layer 243 of the aerosol product article 204 can be heated by various constructions. Note that the average temperature gradient for the two ceramic first (i.e., insulating) layers was 108.5 ns / °C, and the average temperature gradient for the two glass layers was 113.5 ns / °C. The average temperature gradient for the two PEEK layers was 117.5 ns / °C.

[0147] The average time to reach maximum temperature was determined to be 2.2 seconds for the ceramic first (i.e., insulating) layer, 1.9 seconds for the glass first (i.e., insulating) layer, and 2.6 seconds for the PEEK first (i.e., insulating) layer.

[0148] Accordingly, it has been found to be particularly beneficial to utilize either a ceramic or glass layer for the first (i.e., insulating) layer 503. A first (i.e., insulating) layer of PEEK may also be used, providing an improvement in time to first puff compared to configurations in which no first (i.e., insulating) layer is provided between the induction coil(s) and the aerosol product article.

[0149] FIG. 9A shows a table illustrating the performance of different test first (i.e., insulating) layers and the time it took for the surface of the foil susceptor layer of the aerosol product to reach the maximum desired set point temperature of 300° C., and FIG. 9B shows how the temperature of the aluminum foil susceptor layer of the aerosol product changed over time using different test first (i.e., insulating) layers.

[0150] The average time to reach maximum temperature was determined to be 3.5 seconds for the ceramic first (i.e., insulating) layer, 3.0 seconds for the glass first (i.e., insulating) layer, and 3.2 seconds for the PEEK first (i.e., insulating) layer.

[0151] FIG. 10A shows a table illustrating the performance of the first (i.e., insulating) layer for different tests and the time it took for the surface of the layer of aerosol-generating material (gel) of the aerosol product article to reach the maximum desired set point temperature of 300° C., and FIG. 10B shows how the temperature of the surface of the layer of aerosol-generating material changed over time using the first (i.e., insulating) layer for different tests.

[0152] The average time to reach maximum temperature was determined to be 3.8 seconds for the ceramic first (i.e., insulating) layer, 4.0 seconds for the glass first (i.e., insulating) layer, and 4.0 seconds for the PEEK first (i.e., insulating) layer.

[0153] 11 shows an exaggerated view of one configuration of a first (or insulating) layer 503 having a concave first (or upper) surface and a planar second (or lower) surface. The first (or insulating) layer 503 is disposed adjacent to one or more induction coils 501. According to one configuration, a curved aerosol product article 204 may be disposed on the first (or insulating) layer 503 such that when the aerosol product article 204 is heated, the aerosol product article 204 expands and a susceptor layer 506 disposed within the aerosol product article 204 bends from a curved shape to a planar configuration. As a result, the separation distance between the susceptor layer 506 and the one or more induction coils 501 is substantially constant at a desired operating temperature, thereby maintaining a more uniform heating performance.

[0154] According to one configuration, the aerosol chamber (not shown) may have a planar or convex profile and may engage at least a portion or substantially the entire aerosol product article 204 to press the aerosol product article 204 against a first (or upper) surface of the first (i.e., insulating) layer 503. The aerosol chamber may be shaped or deformable such that the susceptor layer 506 assumes a profile (e.g., planar) that substantially corresponds to the profile of the one or more induction coils 501 to allow the aerosol product article to expand as it is heated and such that the separation distance between the susceptor layer 506 and the one or more induction coils 501 is constant.

[0155] 12 shows a further configuration in which a concave first (i.e., insulating) layer 503 is provided. The concave first (i.e., insulating) layer 503 may be provided on a corresponding concave-shaped inductor coil 501. An aerosol product article 204 having a similar profile is disposed on the first (i.e., insulating) layer 503. With this configuration, when it is desired to generate an aerosol from the aerosol product article 204, the distance between the susceptor layer disposed within the aerosol product article 204 and the inductor coil 501 may be maintained substantially constant.

[0156] According to one configuration, the aerosol chamber (not shown) may have a convex profile and may be engaged with the aerosol product article 204 to press the aerosol product article 204 against a first (or upper) surface of the first (i.e., insulating) layer 503. The aerosol chamber may prevent the aerosol product article 204 from deforming, such that a separation distance between a susceptor layer provided within the aerosol product article 204 and the one or more induction coils 501 remains substantially constant.

[0157] Other configurations are contemplated in which the aerosol generator may comprise one or more conductive tracks provided on and / or within the first (i.e., insulating) layer 503. For example, FIG. 13A shows a configuration in which one or more inductor coils 501 are bonded to the second (lower) surface of the first (i.e., insulating) layer 503. One or more conductive tracks may be printed, etched, or deposited on the first (i.e., insulating) layer 503, which may comprise a glass, ceramic, or plastic material such as PEEK. As shown in FIG. 13B, a configuration is also contemplated in which one or more inductive coils 501 may be embedded within the first (i.e., insulating) layer 503. According to this configuration, the one or more inductive coils 501 may be thermally insulated or insulated and may be prevented from distorting, e.g., bending, during operation. The first (i.e., insulating) layer 503 may comprise a plastic material such as PEEK, for example.

[0158] It will be appreciated that various configurations are contemplated in which the aerosol delivery device 202 is provided with a thermal insulation or insulating layer 501 disposed intermediate the one or more induction coils 501 and the aerosol product 204. The first (i.e., insulating) layer 503 may include a glass layer, a ceramic layer, a plastic layer such as polyetheretherketone (PEEK), or another material that may function as an insulator and have a relatively low coefficient of expansion. According to various configurations, the first (i.e., insulating) layer 501 may be a material having a low linear coefficient of expansion, e.g., 10 -6 / °C.

[0159] The first (i.e., insulating) layer may have a concave, convex or planar first (or upper) surface that may be in contact with the aerosol delivery device in use. The first (i.e., insulating) layer may have a concave, convex or planar lower or second surface that may be placed in contact with one or more inductive coils 501. The one or more inductive coils 501 may be provided on a printed circuit board ("PCB").

[0160] The first (or upper) and / or second (or lower) surfaces of the first (i.e., insulating) layer 501 may comprise a plurality of castellations that may provide additional air gaps between the aerosol product article 204 and the one or more inductor coils 501. The first (i.e., insulating) layer 501 of various constructions may have improved resistance to thermal cycling and may help ensure that the aerosol product article 204 disposed within the aerosol delivery device 202 retains thermal energy and that less thermal energy is dissipated within the body of the aerosol delivery device 202 during use. As a result, the aerosol delivery device 202 may generate a first puff from the aerosol product article 204 in a short period of time (as the thermal energy is more retained within the aerosol product article), and the heating performance of the aerosol delivery device is substantially consistent from one use session to the next. It will therefore be appreciated that an aerosol delivery device incorporating a first (i.e., insulating) layer between the aerosol product article and the one or more inductor coils is particularly beneficial.

[0161] According to various embodiments, the aerosol product article may comprise a generally circular or elliptical substrate having a first surface and a second surface. The substrate may comprise, for example, paper, card or aluminum foil. Other embodiments are contemplated in which the substrate may comprise multiple layers arranged in a sandwich. For example, the substrate may comprise a paper or card substrate having a first aluminum foil layer arranged on a first surface and a second aluminum foil layer arranged on a second surface.

[0162] The aerosol product article may include an open-type or closed-type consumable. For example, it will be understood that an open-type consumable is a type of consumable including an aerosol product article in which an aerosol-generating material is provided on one or more outer or outermost surfaces of the aerosol product article. In contrast, it will be understood that a closed-type consumable includes an aerosol product article in which an aerosol-generating material is not provided on the outer or outermost surface of the consumable, but rather on one or more inner surfaces. For example, according to various embodiments, a closed-type consumable may be provided in which one or both of the outer or outermost surfaces of the aerosol product article include a gas-impermeable layer, such as a plastic or other material. For example, an aerosol product article is provided that includes an innermost substrate having one or more layers of aerosol-generating material provided on one or both sides of the substrate, and the aerosol product article is enclosed or otherwise contained within a housing made of a gas-impermeable material is contemplated. A closed-type consumable may include a housing having an air inlet and an aerosol outlet. The aerosol outlet may include a mouthpiece.

[0163] According to various embodiments, the aerosol product article may have a length (L), a width (W) and a thickness (T), where the length (L) of the aerosol product article is greater than the width (W) and / or the thickness (T). The aerosol product article may have a longitudinal axis and may have a first air flow input end and a second air flow output end. For example, the aerosol product article may comprise a prism having a first end face and a second end face. The first end face may comprise an area where air enters the aerosol product article in use, and the second end face may comprise an area where aerosol generated within the aerosol product article exits the aerosol product article in use.

[0164] Embodiments are contemplated in which the second end surface further comprises a mouthpiece. For example, the aerosol product article may comprise a distal end (which may be configured to allow air to enter the aerosol product article through which) and a proximal end (which may comprise a mouthpiece through which a user may inhale aerosol generated within the aerosol product article).

[0165] According to various embodiments, the aerosol generating material may be provided on either the first surface and / or the second surface of the substrate. For example, a single-sided or double-sided aerosol product article may be provided. A single-sided aerosol product article may be operated by a single arrangement of heating elements. A double-sided aerosol product article may be operated by a dual arrangement of heating elements provided on both sides of the aerosol product article during use.

[0166] Embodiments are contemplated in which the aerosol product article may be rotated and / or translated relative to the one or more aerosol generators. The one or more aerosol generators may include, for example, a single aerosol generator, or multiple aerosol generators may be arranged, for example, in an array. The aerosol generators may be provided in an n×m array, where n=2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10, and m=2, 3, 4, 5, 6, 7, 8, 9, 10, or more than 10, embodiments are contemplated. For example, the aerosol generators may be provided in a 2×2 array, a 2×3 array, a 2×4 array, a 2×5 array, a 2×6 array, a 2×7 array, a 2×8 array, a 2×9 array, or a 2×10 array.

[0167] According to various embodiments, the one or more aerosol generators may comprise one or more resistive heaters or resistive heating elements. According to other embodiments, the one or more aerosol generators may comprise one or more inductive heaters or inductive heating elements. Embodiments in which multiple resistive and inductive heating elements may be provided are also contemplated.

[0168] The aerosol product article may be configured to be rotated and / or translated relative to the one or more aerosol generators such that the aerosol product article is disposed adjacent to the one or more aerosol generators and heated from only one side. Alternatively, the aerosol product article may be configured to be rotated and / or translated relative to the one or more aerosol generators such that the aerosol product article is inserted between a first set of aerosol generators and a second set of aerosol generators. According to such an embodiment, the aerosol product article may be configured to be heated from two opposing sides simultaneously or sequentially.

[0169] Also contemplated are embodiments in which the aerosol product article may be prismatic. For example, the aerosol product article may include a triangular prism, a square prism, or a cylindrical prism. For example, the aerosol product article may include a cylindrical aerosol product article. The aerosol product article may be rotated and / or translated relative to one or more aerosol generators. For example, the aerosol delivery device may include a cavity into which a prismatic or cylindrical aerosol product article may be inserted. A matrix, strip, or array of aerosol generators may be provided at one or more locations around or along the cavity. The aerosol product article may then be rotated and / or translated relative to the aerosol generator such that different portions of the aerosol product article may be heated or otherwise accessed sequentially or incrementally.

[0170] Embodiments are contemplated in which the aerosol product article may be translated relative to one or more aerosol generators. For example, the aerosol product article may comprise multiple portions of aerosol-generating material, and the aerosol product article may be translated longitudinally such that multiple separate portions of the aerosol-generating material may be actuated or otherwise heated in series or sequentially.

[0171] Further embodiments are contemplated in which the aerosol-generating article may comprise a cylinder or more generally a prism. A plurality of aerosol generators may be arranged around or centered on a cylindrical or prismatic aerosol-generating article. It is contemplated that the aerosol-generating article may be rotated within a static array of aerosol generators. Alternatively, the aerosol-generating article may remain stationary and a plurality of aerosol generators may be rotated relative to the aerosol-generating article. Yet another embodiment is contemplated in which both the aerosol-generating article and one or more aerosol generators are movable. For example, the aerosol-generating article may be rotated and / or translated at a first speed v1 and one or more aerosol generators may be rotated and / or translated at a second speed v2. Embodiments are contemplated in which v1>v2 in the operating mode. Embodiments are contemplated in which v1=v2 in the operating mode. Embodiments in which v1<v2 in the operating mode are also contemplated.

[0172] According to various embodiments, the aerosol-generating article may comprise a flat or planar consumable having a longitudinal axis. The aerosol-generating article may be translated in a direction parallel to the longitudinal axis. Other embodiments are contemplated in which the aerosol-generating article comprises a cylindrical consumable having a longitudinal axis. The cylindrical consumable may be rotated about its longitudinal axis and / or translated in a direction parallel to the longitudinal axis. The aerosol-generating article may be single-sided or double-sided. The double-sided consumable may be heated from both sides during use.

[0173] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present 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. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. An aerosol delivery device comprising: An aerosol generator; a receiving area for receiving the aerosol product; a first layer disposed between the aerosol generator and the receiving area; An aerosol delivery device comprising:

2. The aerosol delivery device of claim 1 , wherein the first layer comprises a thermal insulating layer.

3. The aerosol delivery device of claim 1 or 2, wherein the first layer comprises one or more layers of glass.

4. The aerosol delivery device of claim 1 , 2 or 3 , wherein the first layer comprises one or more ceramic layers.

5. The aerosol delivery device of any one of claims 1 to 4, wherein the first layer comprises a combination of one or more glass layers and one or more ceramic layers.

6. 6. The aerosol delivery device of claim 1, wherein the first layer has a thermal conductivity of less than 0.01 W / mK, 0.01-0.05 W / mK, 0.05-0.1 W / mK, 0.1-0.5 W / mK, 0.5-1 W / mK, 1-5 W / mK, 5-10 W / mK, 10-20 W / mK, 20-30 W / mK, 30-40 W / mK, or 40-50 W / mK.

7. 7. The aerosol delivery device of claim 1, wherein the first layer has a flatness of ±1 μm, ±1-5 μm, ±5-10 μm, ±10-15 μm, ±15-20 μm or ±20-25 μm over an area of ​​10 mm x 10 mm.

8. 8. The aerosol delivery device of claim 1, wherein the first layer has a flatness tolerance of less than 1 μm, 1-5 μm, 5-10 μm, 10-15 μm, 15-20 μm, or 20-25 μm.

9. The aerosol delivery device of any one of claims 1 to 8, wherein the first or lower surface of the first layer comprises a plurality of castellations or regular protrusions.

10. The aerosol delivery device of claim 9 , wherein the plurality of castellations or regular protrusions form an air gap or air insulating layer.

11. 11. The aerosol delivery device of claim 10, wherein the air gap or air insulating layer is less than 50 μm, 50-100 μm, 100-150 μm, 150-200 μm, 200-250 μm, 250-300 μm, 300-350 μm, 350-400 μm, or greater than 400 μm thick.

12. 12. The aerosol delivery device of claim 1, wherein the first layer is less than 50 μm, 50-100 μm, 100-150 μm, 150-200 μm, 200-250 μm, 250-300 μm, 300-350 μm, 350-400 μm, 400-450 μm, 450-500 μm, 500-550 μm, 550-600 μm, or greater than 600 μm thick.

13. The aerosol delivery device of any one of claims 1 to 12, wherein the first or upper surface of the first layer comprises one or more depressions.

14. The aerosol delivery device of any one of claims 1 to 13, wherein the first layer is magnetically permeable.

15. The first layer is 10×10 －６ 15. The aerosol delivery device of claim 1, having a thermal expansion coefficient of less than 40 / °C (40-400°C).

16. 16. The aerosol delivery device of any one of claims 1 to 15, wherein the first layer has a stiffness or Young's modulus in the range of 50-60 GPa, 60-70 GPa, 70-80 GPa, 80-90 GPa, 90-100 GPa, or greater than 100 GPa.

17. 17. The aerosol delivery device of any one of claims 1 to 16, wherein the first layer protrudes from a surrounding housing, such that, in use, an aerosol product contacts the first layer but not the surrounding housing.

18. 18. The aerosol delivery device of claim 1, wherein the aerosol generator comprises one or more induction heating elements, the one or more induction heating elements being at least partially embedded within the first layer.

19. 19. The aerosol delivery device of any one of claims 1 to 18, wherein the aerosol generator comprises one or more conductive tracks provided on and / or within the first layer.

20. 20. The aerosol delivery device of any one of claims 1 to 19, wherein the first or upper surface of the first layer is convex, concave or planar.

21. 21. The aerosol delivery device of any one of claims 1 to 20, wherein the second or lower surface of the first layer is convex, concave or planar.

22. 22. The aerosol delivery device of any one of claims 1 to 21, wherein the aerosol generator comprises one or more convex, concave or planar induction coils.

23. The aerosol delivery device of any one of claims 1 to 22, wherein the first layer is impermeable to gas.

24. 1. An aerosol generating system comprising: An aerosol delivery device according to any one of claims 1 to 23; an aerosol product; An aerosol generating system comprising:

25. The aerosol product comprises: (i) a substantially circular, elliptical, or polyhedral substrate having one or more portions of an aerosol-generating material disposed on a first surface of the substrate and / or one or more portions of an aerosol-generating material disposed on a second surface of the substrate; (ii) a substantially planar substrate having one or more portions of an aerosol-forming material disposed on a first surface of the substrate and / or one or more portions of an aerosol-forming material disposed on a second surface of the substrate; or (iii) Aerosol products having a prismatic or cylindrical shape 25. The aerosol generating system of claim 24, comprising:

26. 26. The aerosol generating system of claim 24 or 25, wherein the aerosol product comprises either an open consumable or a closed consumable.

27. 1. A method for generating an aerosol, comprising: providing an aerosol delivery device comprising an aerosol generator having a receiving area for receiving an aerosol product and a first layer between the aerosol generator and the receiving area; inserting an aerosol product into the receiving area; A method comprising:

28. 1. An aerosol delivery device comprising: a receiving area for receiving the aerosol product; one or more first aerosol generators disposed on a first side of the receiving area; one or more second aerosol generators disposed on a second side of the receiving area; An aerosol delivery device comprising:

29. 30. The aerosol delivery device of claim 28, further comprising a first thermal insulation layer disposed between the one or more first aerosol generators and the receiving area.

30. 30. The aerosol delivery device of claim 29, wherein the first thermal insulation layer has a plurality of castellations or regular protrusions that form an air gap or air insulation layer.

31. 31. The aerosol delivery device of claim 28, 29, or 30, further comprising a second thermal insulation layer disposed between the one or more second aerosol generators and the receiving area.

32. 32. The aerosol delivery device of claim 31, wherein the second thermal insulation layer has a plurality of castellations or regular protrusions that form an air gap or air insulation layer.

33. 1. An aerosol delivery device comprising: one or more aerosol generators; a receiving area for receiving the aerosol product; a first thermal insulation layer disposed between the one or more aerosol generators and the receiving area, the first thermal insulation layer having a first side facing the receiving area and a second side opposite the receiving area, the first thermal insulation layer further comprising: (i) providing a plurality of castellations, regular protrusions or depressions on the first side of the first thermal insulation layer to form an air gap or air insulating layer between the first thermal insulation layer and the aerosol product article when the aerosol product article is placed in the receiving area in use; and / or (ii) forming a plurality of castellations, regular protrusions or depressions on the second side of the first thermal insulation layer to form an air gap or air insulation layer between the first thermal insulation layer and the one or more aerosol generators; a first thermal insulation layer; An aerosol delivery device comprising:

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