Aerosol-generating article comprising a piezoelectric component

Abstract

The aerosol-generating article (200) comprises an atomizer for atomizing a liquid aerosol-forming substrate to generate an aerosol. The atomizer comprises a piezoelectric component (100). The piezoelectric component (100) comprises an actuator (102) and a porous element (104). The actuator (102) is arranged to vibrate the porous element (104) to generate the aerosol. The porous element (104) is a freeze-cast porous element.

Description

[Technical Field]

[0001] The present invention relates to aerosol-generating articles. In particular, the present invention relates to aerosol-generating articles that can be used to generate aerosols by non-thermal vaporization. Summary of the Invention

[0002] One type of aerosol-generating system is an electrically operated smoking system. Handheld electrically operated smoking systems are known, consisting of an aerosol-generating device with a battery and control electronics, and an aerosol-generating article with a supply of aerosol-forming substrate and an electrically operated vaporizer. Aerosol-generating articles, such as cartridges, that include both a supply of aerosol-forming substrate and a vaporizer are sometimes called "cartomizers." Such aerosol-generating articles may include not only a supply of aerosol-forming substrate and an electrically operated vaporizer, but also a mouthpiece that a user draws on to inhale the aerosol into their mouth during use.

[0003] The vaporizer may be configured to vaporize the aerosol-forming substrate by a variety of methods, which can be divided into either thermal or non-thermal vaporization.

[0004] Thermal vaporization involves heating the aerosol-forming substrate until it vaporizes. Vaporizers for thermally vaporizing an aerosol-forming substrate typically comprise a coil of heater wire wrapped around an elongated core that is immersed in the liquid aerosol-forming substrate.

[0005] Non-thermal vaporization generates an aerosol without the use of heat. One example of non-thermal vaporization is ultrasonic nebulization, which may involve forcing an aerosol-forming substrate through a porous membrane vibrated by a piezoelectric actuator.

[0006] Arrangements for non-thermal vaporization can be difficult to manufacture: for example, a typical manufacturing method involves casting a membrane from metal, drilling small holes in the membrane to form a porous membrane, and attaching the porous membrane to a piezoelectric actuator.

[0007] It would be desirable to provide an aerosol-generating article that is suitable for non-thermal vaporization of an aerosol-forming substrate and that is simple to manufacture.

[0008] An aerosol-generating article is provided that includes a piezoelectric component, the piezoelectric component comprising an atomizer for atomizing a liquid aerosol-forming substrate to generate an aerosol, the atomizer comprising an actuator and a porous element, the actuator being arranged to vibrate the porous element to generate the aerosol, and the porous element being a freeze-cast porous element.

[0009] An aerosol-generating article is also provided. The aerosol-generating article may comprise an atomizer for atomizing a liquid aerosol-forming substrate to generate an aerosol. The atomizer may comprise a piezoelectric component. The piezoelectric component may comprise an actuator. The piezoelectric component may comprise a porous element. The actuator may be arranged to vibrate the porous element to generate the aerosol. The porous element is a freeze-cast porous element.

[0010] Also provided is an aerosol-generating system comprising an aerosol-generating device and an aerosol-generating article, the aerosol-generating article comprising an atomizer for atomizing a liquid aerosol-forming substrate to generate an aerosol, the atomizer comprising a piezoelectric component comprising an actuator and a porous element, the porous element being a freeze-cast porous element.

[0011] Also provided is an aerosol-generating system. The aerosol-generating system may comprise an aerosol-generating device and an aerosol-generating article. The aerosol-generating article may comprise an atomizer for atomizing a liquid aerosol-forming substrate to generate an aerosol. The atomizer may comprise a piezoelectric component. The piezoelectric component may comprise an actuator. The piezoelectric component may comprise a porous element. The actuator may be arranged to vibrate the porous element to generate the aerosol. The porous element is a freeze-cast porous element.

[0012] Pores in a porous element are typically formed by drilling. Advantageously, forming a porous element by using freeze casting may allow the pores in the porous element to be formed as the porous element itself is formed. As a result, an easier and more straightforward manufacturing process may be provided compared to typical manufacturing processes, since the additional step of drilling holes in the porous element is eliminated.

[0013] Additionally, using freeze casting to form the pores may allow for the formation of smaller pores than is possible with conventional drilling.

[0014] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate or through non-thermal means.

[0015] As used herein, the term "porous" means formed from a material that has a plurality of openings and is permeable to the liquid aerosol-forming substrate and the openings allow the liquid aerosol-forming substrate to move therethrough.

[0016] As used herein, the term "pore" refers to an opening in a porous material.

[0017] As used herein, the term "porous element" refers to a component of an aerosol-generating article that has a plurality of pores.

[0018] As used herein, the term "freeze-cast porous element" is a porous element formed by the method of freeze-casting.

[0019] The aerosol-generating article may be a cartridge.

[0020] The aerosol-generating article may comprise a housing. The housing may be a rigid housing. The housing may comprise a liquid reservoir. The housing may define a liquid reservoir. The liquid reservoir may hold a quantity of liquid aerosol-forming substrate.

[0021] The liquid aerosol-forming substrate may be adsorbed or otherwise loaded onto a carrier or support. The carrier may comprise a carrier material. The carrier material may be made of any suitable absorbent plug or body, such as foamed metal or plastic material, polypropylene, terylene, nylon fiber, or ceramic.

[0022] The aerosol-generating article may comprise a transport body. The transport body may be suitable for transporting the aerosol-forming substrate to the piezoelectric component. The transport body may comprise a porous material. The transport body may comprise a first portion and a second portion. The first portion of the transport body may extend into the reservoir. The second portion of the transport body may be adjacent to the piezoelectric component.

[0023] The liquid storage portion may include an opening. The porous element may extend across the opening of the liquid storage portion. The porous element may extend completely across the opening of the liquid storage portion. Alternatively, in some embodiments, the porous element may extend partially across the opening of the liquid storage portion.

[0024] The actuator may comprise one or more actuators. The actuator may comprise a plurality of actuators.

[0025] The actuator may be any type of actuator for exciting vibrations in the porous element.

[0026] The actuator may comprise a piezoelectric actuator. The actuator may comprise one or more piezoelectric actuators. The actuator may comprise a plurality of piezoelectric actuators.

[0027] Piezoelectric actuator refers to a piezoelectric (piezo-electric) actuator. Piezoelectric actuators are preferred because they provide an energy-efficient and lightweight means of inducing vibration in a porous element and have a high efficiency of energy conversion from electricity to acoustic / mechanical output. Furthermore, piezoelectric actuators are available in a wide variety of materials and shapes. For piezoelectric actuators, inputting an electrical drive signal into the piezoelectric actuator results in a mechanical output in the form of a vibration signal.

[0028] Tuning and adjusting the electrical drive signal input to the piezoelectric actuator may result in corresponding changes in the output vibration signal, thereby allowing the actuator to activate different vibration modes of the porous element.

[0029] Other types of actuators or transducers may be employed. For example, the actuator may comprise one or more magnetostrictive transducers. The actuator may comprise one or more electrostrictive transducers. The actuator may comprise one or more piezomagnetic transducers.

[0030] Combinations of different types of actuators or transducers are possible, for example in layered or parallel configurations.

[0031] The actuator may be disposed at any suitable location relative to the porous element. The actuator may be disposed to transmit vibrations to the porous element on the inlet side or outlet side of the porous element. The actuator may be disposed to transmit vibrations to the porous element on the inlet side. The actuator may be disposed to transmit vibrations to the porous element on the outlet side.

[0032] The actuator may be arranged to vibrate the porous element in any suitable direction. The actuator may be arranged to vibrate the porous element in a thickness direction. As used herein, "thickness direction" means a direction substantially parallel to the thickness of the porous element. This may facilitate deformation of the porous element that promotes movement of the liquid aerosol-forming substrate through the passages in the porous element.

[0033] The actuator may include one or more drive elements. The one or more drive elements may be of any suitable shape. The one or more drive elements may be substantially circular or elliptical. The one or more drive elements may be substantially triangular, square, or any regular or irregular shape. The one or more drive elements may be annular. The one or more drive elements may substantially surround multiple passages in the porous element. By surrounding multiple passages in the porous element, the one or more drive elements may not cover the open ends of the passages. The one or more drive elements may be substantially flat. The one or more drive elements may have a thickness of about 0.1 mm to 5.0 mm. The one or more drive elements may be substantially annular disks. The outer diameter of the annular disk may be about 3 mm to about 60 mm, and the inner diameter may be about 2 mm to about 59 mm.

[0034] The actuator may be attached to one side of the porous element. The actuator may be attached to both sides of the porous element.

[0035] The porous element may be formed by freeze-cast sintering, in other words, the porous element may be a freeze-cast sintered porous element.

[0036] The porous element may comprise a plurality of pores, and in this way the porous element is fluid permeable. The porous element may comprise a plurality of passages.

[0037] As used herein, the term "fluid permeable" with respect to a porous element means that the porous element allows a fluid, e.g., a gas or liquid, to pass through it. For example, the porous element may allow a liquid aerosol-forming substrate to pass through its pores.

[0038] The porous element may be a porous membrane. The porous element may be a vibratable element.

[0039] The porous element may be a perforated plate. The perforated plate may be a perforated plate.

[0040] The porous element may be a thin sheet. As used herein, "thin" refers to a body having a thickness that is substantially less than other dimensions of the body, such as length, width, or diameter. The porous element may have a thickness of about 0.1 mm to about 4.0 mm. The porous element may have a longitudinal length or diameter of about 3 mm to about 60 mm.

[0041] As used herein, the term "diameter" refers to the largest transverse dimension of a part, or portion of a part, of an aerosol-generating article.

[0042] The porous element may be of any suitable shape. The porous element may be substantially circular or elliptical. The porous element may be substantially triangular, or square, or any regular or irregular shape. The porous element may be substantially flat. The porous element may be curved. The porous element may be dome-shaped. The porous element may be a substantially square plate. The porous element may be a substantially circular or elliptical disk.

[0043] The porous element may have an inlet side and an opposite outlet side, and each pore or passage in the porous element may extend between the inlet side and the outlet side.

[0044] The porous element may include a plurality of pores or passages.

[0045] The plurality of pores may have an average diameter of 10 micrometers or less. The plurality of pores may have an average diameter of 15 micrometers or less. The plurality of pores may have an average diameter of 20 micrometers or less. The plurality of pores may have an average diameter of 25 micrometers or less. The plurality of pores may have an average diameter of 30 micrometers or less.

[0046] The plurality of pores may have an average diameter of at least 5 micrometers. The plurality of pores may have an average diameter of at least 10 micrometers.

[0047] The plurality of pores may have an average diameter of 10 micrometers to 30 micrometers.

[0048] The porous element may have at least 50 percent of its pores having an average diameter of 10 micrometers or less. The porous element may have at least 55 percent of its pores having an average diameter of 10 micrometers or less. The porous element may have at least 60 percent of its pores having an average diameter of 10 micrometers or less. The porous element may have at least 65 percent of its pores having an average diameter of 10 micrometers or less. The porous element may have at least 70 percent of its pores having an average diameter of 10 micrometers or less. The porous element may have at least 75 percent of its pores having an average diameter of 10 micrometers or less.

[0049] The porous element may have at least 50 percent of its pores having an average diameter of 20 micrometers or less. The porous element may have at least 55 percent of its pores having an average diameter of 20 micrometers or less. The porous element may have at least 60 percent of its pores having an average diameter of 20 micrometers or less. The porous element may have at least 65 percent of its pores having an average diameter of 20 micrometers or less. The porous element may have at least 70 percent of its pores having an average diameter of 20 micrometers or less. The porous element may have at least 75 percent of its pores having an average diameter of 20 micrometers or less.

[0050] The porous element may have at least 50 percent of its pores having an average diameter of 30 micrometers or less. The porous element may have at least 55 percent of its pores having an average diameter of 30 micrometers or less. The porous element may have at least 60 percent of its pores having an average diameter of 30 micrometers or less. The porous element may have at least 65 percent of its pores having an average diameter of 30 micrometers or less. The porous element may have at least 70 percent of its pores having an average diameter of 30 micrometers or less. The porous element may have at least 75 percent of its pores having an average diameter of 30 micrometers or less.

[0051] The porous element may be prepared by a process including the steps of preparing a slurry by mixing aluminum oxide with liquid camphene, heating the slurry to 40 to 50 degrees Celsius to form a warmed slurry, heating a mold to 40 to 50 degrees Celsius, pouring the warmed slurry into the mold, and placing the mold on an ice block having a temperature of minus 25 to minus 30 degrees Celsius for a period of 2 to 15 minutes so that the slurry freezes and the temperature of the slurry drops to minus 2 to minus 20 degrees Celsius.

[0052] The porous element may be provided with a metal coating.

[0053] The metal coating may comprise nickel. The porous element may comprise a nickel coating. The metal coating may comprise platinum. The porous element may comprise a platinum coating. The metal coating may comprise titanium. The porous element may comprise a titanium coating. The metal coating may comprise silver. The porous element may comprise a silver coating. The metal coating may comprise gold. The porous element may comprise a gold coating.

[0054] The piezoelectric component may be assembled by attaching one or more actuators to a porous element, which may be attached to the porous element by any suitable means, such as by using an adhesive.

[0055] In one embodiment, the porous element may be formed or grown directly on one or more actuators.

[0056] The piezoelectric component may comprise a non-porous element. The non-porous element may be substantially fluid-impermeable. As used herein, the term "fluid-impermeable" with respect to a non-porous element means that the non-porous element does not allow a fluid, e.g., a gas or liquid, to pass through it.

[0057] The non-porous element may comprise a metal. The non-porous element may be ring-shaped. The non-porous element may be disc-shaped.

[0058] The piezoelectric component may comprise one or more porous elements attached to a non-porous element. The piezoelectric component may comprise a disk-shaped porous element attached to the center of a ring-shaped non-porous element. The piezoelectric component may comprise a disk-shaped non-porous element attached to the center of a ring-shaped porous element. The piezoelectric component may comprise a ring-shaped non-porous element attached to the center of a ring-shaped porous element.

[0059] The piezoelectric component may comprise a ring-shaped non-porous element attached to the center of a ring-shaped porous element, and a second disk-shaped porous element attached to the center of the ring-shaped non-porous element.

[0060] The piezoelectric component may be assembled by attaching one or more actuators to a non-porous element and then attaching the non-porous element to a porous element. The one or more actuators may be attached to the non-porous element by any suitable means, such as by using an adhesive. The non-porous element may be attached to the porous element by any suitable means, such as by using an adhesive.

[0061] Advantageously, providing a non-porous element may limit or focus aerosol generation to the area where the porous element is provided.

[0062] The piezoelectric component may comprise a plurality of porous elements, each of which may be as described above.

[0063] The aerosol-forming substrate may be a liquid aerosol-forming substrate. A liquid aerosol-forming substrate, also known as an e-liquid, is a liquid substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate.

[0064] The aerosol-forming substrate may comprise a plant-derived material.

[0065] The aerosol-forming substrate may comprise tobacco.

[0066] The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds that are released from the aerosol-forming substrate upon vaporisation.

[0067] Alternatively, the aerosol-forming substrate may comprise a non-tobacco-containing material.

[0068] The aerosol-forming substrate may comprise a homogenized plant-derived material.The aerosol-forming substrate may comprise a homogenized tobacco material.

[0069] The aerosol-forming substrate may include at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol upon use. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols such as triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols such as glycerol monoacetate, diacetate, or triacetate; and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Preferred aerosol formers are polyhydric alcohols or mixtures thereof, such as triethylene glycol, 1,3-butanediol, and most preferably glycerin.

[0070] The aerosol-forming substrate may also contain other additives and ingredients, such as flavoring agents.

[0071] The aerosol generating device may comprise a body. The body may be rigid. The body may be formed from any suitable material or combination of materials. Examples of suitable materials include, but are not limited to, metals, alloys, plastics, or composites containing one or more of these materials. Preferably, the outer housing is lightweight and not brittle. The aerosol generating device may include a mouthpiece. The body may be shaped to define the mouthpiece. Alternatively, the mouthpiece may comprise a separate component.

[0072] The aerosol generating device may include a chamber for receiving the aerosol-generating article.

[0073] The aerosol generating device may comprise a power supply for providing power to the actuator. The power supply may comprise a battery. The battery may comprise a rechargeable battery.

[0074] The aerosol generating device includes a controller.

[0075] The controller may be configured to control the operation of the aerosol generating device.

[0076] When the aerosol-generating article is received in the aerosol-generating device, the aerosol-generating article may be inverted relative to the orientation of the aerosol-generating device, or alternatively, when the aerosol-generating article is received in the aerosol-generating device, the aerosol-generating article may have the same orientation as the aerosol-generating device.

[0077] During use, a user may operate the aerosol generation system by operating a switch or by sucking on the mouthpiece of the aerosol generating device. Upon operation, the actuator may be activated to excite vibrations in the porous element. The vibrations in the porous element may deform the porous element and the pores within the porous element. A liquid aerosol-forming substrate may be received by the porous element at the inlet side. The deformation of the pores may draw the received liquid aerosol-forming substrate into the pores and expel aerosol droplets of the liquid aerosol-forming substrate from the opposite outlet side of the porous element, aerosolizing the liquid aerosol-forming substrate.

[0078] The invention will be further described with reference to the drawings in the accompanying drawings, in which: [Brief explanation of the drawings]

[0079] [Figure 1] FIG. 1 shows a schematic cross-sectional view of an example of a piezoelectric component according to an embodiment of the present invention. [Figure 2] FIG. 2 shows a schematic cross-sectional view of an example of an aerosol-generating article according to an embodiment of the present invention, the aerosol-generating article including the piezoelectric component shown in FIG. [Figure 3] FIG. 3 shows a schematic cross-sectional view of an example of an aerosol generation system according to an embodiment of the present invention, the aerosol generation system including an aerosol generating device and the aerosol-generating article shown in FIG. [Figure 4]FIG. 4 shows a schematic cross-sectional view of an example of a piezoelectric component according to an embodiment of the present invention. [Figure 5] FIG. 5 shows a schematic cross-sectional view of an example of a piezoelectric component according to an embodiment of the present invention. [Figure 6] FIG. 6 shows a schematic cross-sectional view of an example of a piezoelectric component according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0080] The embodiment of FIG. 1 shows a piezoelectric component 100 .

[0081] Piezoelectric component 100 includes multiple actuators 102. For example, in FIG. 1 , piezoelectric component 100 includes two ring-shaped actuators 102. In this example, each actuator 102 is a piezoelectric actuator. In other examples, each actuator 102 may be another type of actuator, such as a magnetostrictive actuator or an electrostrictive actuator.

[0082] The piezoelectric component 100 also includes a porous element 104. In this embodiment, the porous element 104 is a porous membrane sandwiched between the two actuators 102. The porous element 104 has a plurality of pores. The plurality of pores extends through the porous element 104 from the inlet side 106 to the outlet side 108. In this embodiment, the plurality of pores has an average diameter of 10 micrometers or less. The porous element 104 has a metal coating. In this embodiment, the porous element 104 has a nickel coating.

[0083] The piezoelectric component 100 is assembled by forming a porous element 104 and then attaching multiple actuators 102 to the porous element 104. In this embodiment, the porous element 104 is a freeze-cast porous element formed as a single piece by a freeze-cast process.

[0084] In this embodiment, the porous element 104 is preparing a slurry by mixing aluminum oxide with liquid camphene; heating the slurry to 40 degrees Celsius to form a warmed slurry; heating the mold to 40 degrees Celsius; pouring the warmed slurry into a mold; The slurry is prepared by placing the mold on a block of ice having a temperature of minus 25 degrees Celsius for a period of 15 minutes so that the slurry freezes and the temperature of the slurry drops to minus 20 degrees Celsius.

[0085] The embodiment of Figure 2 shows an aerosol-generating article 200. In this embodiment, the aerosol-generating article 200 is a cartridge. The aerosol-generating article 200 includes a vaporizer for aerosolizing a liquid aerosol-forming substrate. In this embodiment, the vaporizer is the piezoelectric component 100 shown in Figure 1 and described above.

[0086] The aerosol-generating article 200 has a housing 202. The housing 202 contains a liquid storage portion 204. In this embodiment, a liquid aerosol-forming substrate 206 is stored within the liquid storage portion 204. The aerosol-generating article 200 has a transfer body 208 for transferring the liquid aerosol-forming substrate 206 from the liquid storage portion 204 to the piezoelectric component 100. The transfer body 208 contains a porous material and is immersed within the liquid aerosol-forming substrate 206. The transfer body 208 has a first portion 210 and a second portion 212. The first portion 210 extends into the liquid storage portion 204. The second portion 212 is adjacent to the piezoelectric component 100.

[0087] The liquid reservoir 204 has an opening 214 through which the liquid aerosol-forming substrate 206 can be conveyed to the piezoelectric component 100. In this embodiment, the porous element 104 extends across the opening 214.

[0088] The embodiment of Figure 3 shows an aerosol-generating system 300. The aerosol-generating system includes an aerosol-generating device 400 and the aerosol-generating article 200 shown in Figure 2. Figure 3 only shows a portion of the aerosol-generating device 400.

[0089] In this embodiment, the aerosol-generating article 200 is positioned in an inverted position within the aerosol-generating device 400. In another embodiment, the aerosol-generating article 200 may be positioned in the same orientation as the aerosol-generating device 400.

[0090] The aerosol generating device 400 has a body 402. In this embodiment, the body 402 is shaped to define a mouthpiece 404. The body 402 houses a power source. In this embodiment, the power source is a rechargeable battery (not shown). The body 402 also houses a controller 406, which is shown schematically in FIG. 3 . The body 402 also houses an electrical connector (not shown). The electrical connector provides an electrical connection between the aerosol generating device 400 and the aerosol-generating article 200.

[0091] The body 402 has a number of air inlets (not shown) that allow air 408 to flow towards and across the piezoelectric component 100 .

[0092] In use, a user puffs on the mouthpiece 404, which draws air 408 into the aerosol-generating device 400. In response to the user puffing on the mouthpiece 404, the controller 406 activates the piezoelectric component 100. When the piezoelectric component 100 is activated, the actuator 102 vibrates the porous element 104. The vibrations in the porous element 104 deform the porous element 104 and deform the pores within the porous element 104. The liquid aerosol-forming substrate 206 flows from the liquid reservoir 204 through the opening 214 and to the inlet side 106 of the porous element 104 via capillary action through the transport body 208. The vibration draws the liquid aerosol-forming substrate 206 into the pores in the porous element 104 and ejects droplets of the liquid aerosol-forming substrate 206 from the outlet side 108, thereby aerosolizing the liquid aerosol-forming substrate 206 into aerosol 410. The aerosol 410 is drawn toward the mouthpiece 404 by the user's puffing action. The flow of aerosol 410 through the aerosol-generating device 400 and toward the mouthpiece 404 is indicated by 412. The aerosol 410 flows out of the mouthpiece 404 and is inhaled by the user.

[0093] FIG. 4 shows an embodiment of a piezoelectric component 500 having a different arrangement than the piezoelectric component 100 shown in FIG.

[0094] In the embodiment of Figure 4, the piezoelectric component 500 includes multiple actuators 502. For example, in Figure 4, the piezoelectric component 500 includes two ring-shaped actuators 502. In this embodiment, each actuator 502 is a piezoelectric actuator.

[0095] The piezoelectric component 500 also includes a porous element 504. In this example, the porous element 504 is a porous membrane. The porous element 504 has a plurality of pores. The plurality of pores extends through the porous element 504 from an inlet side 506 to an outlet side 508. In this example, the plurality of pores has an average diameter of 10 micrometers or less.

[0096] The piezoelectric component 500 also includes a non-porous element 510. In this embodiment, the non-porous element 510 is a metallic ring-shaped element sandwiched between the two actuators 502.

[0097] The piezoelectric component 500 of FIG. 4 is assembled by 1) forming a porous element 504, 2) forming a non-porous element 510, 3) attaching the non-porous element 510 to a plurality of actuators 502, and 4) attaching the porous element 504 to the non-porous element 510.

[0098] In this embodiment, the porous element 504 is a freeze-cast porous element formed as a single piece by a freeze-cast process.

[0099] 4 may be that the diameter of the porous element 504 can be controlled during the manufacturing process, allowing for control of the aerosol that can be produced by the piezoelectric component 500. For example, because aerosol generation is limited to the area of ​​the porous element 504, the direction and volume of the aerosol can be controlled by varying the diameter of the porous element 504.

[0100] 4 may be simple to manufacture because the actuator 502 is not attached directly to the porous element 504, but instead is attached directly to the non-porous element 510. Attaching the actuator 502 directly to the porous element 504 may require a special type of glue, which may increase the cost and complexity of the manufacturing process.

[0101] FIG. 5 shows an embodiment of a piezoelectric component 600 having a different arrangement than the piezoelectric component 100 shown in FIG.

[0102] In the embodiment of Figure 5, the piezoelectric component 600 includes multiple actuators 602. For example, in Figure 5, the piezoelectric component 600 includes two ring-shaped actuators 602. In this embodiment, each actuator 602 is a piezoelectric actuator.

[0103] The piezoelectric component 600 also includes a porous element 604. In this embodiment, the porous element 604 is a ring-shaped porous membrane. The porous element 604 is sandwiched between two actuators 602. The porous element 604 has a plurality of pores. The plurality of pores extends through the porous element 604 from an inlet side 606 to an outlet side 608. In this embodiment, the plurality of pores has an average diameter of 10 micrometers or less.

[0104] Piezoelectric component 600 also includes a non-porous element 610. In this embodiment, non-porous element 610 is a metallic disk-shaped element attached to the center of porous element 604.

[0105] The piezoelectric component 600 of FIG. 5 is assembled by 1) forming a porous element 604, 2) forming a non-porous element 610, 3) attaching the porous element 604 to a plurality of actuators 602, and 4) attaching the non-porous element 610 to the porous element 604.

[0106] In this embodiment, porous element 600 is a freeze-cast porous element formed as a single piece by a freeze-cast process.

[0107] 5 may be that the shape of the porous element 604 can be controlled during the manufacturing process to allow for control of the aerosol that can be produced by the piezoelectric component 600. For example, because aerosol generation is limited to the area of ​​the porous element 604, the direction and volume of the aerosol can be controlled.

[0108] FIG. 6 shows an embodiment of a piezoelectric component 700 having a different arrangement than the piezoelectric component 100 shown in FIG.

[0109] In the embodiment of Figure 6, the piezoelectric component 700 includes multiple actuators 702. For example, in Figure 6, the piezoelectric component 700 includes two ring-shaped actuators 702. In this embodiment, each actuator 702 is a piezoelectric actuator.

[0110] The piezoelectric component 700 also includes a plurality of porous elements 704. In this example, the piezoelectric component 700 includes a first porous element 704a and a second porous element 704b. Each porous element 704a, 704b is a ring-shaped porous membrane. Each porous element 704a, 704b has a plurality of pores. The plurality of pores extend through the porous elements 704a, 704b from the inlet side 706 to the outlet side 708. In this example, the plurality of pores has an average diameter of 10 micrometers or less.

[0111] Piezoelectric component 700 also includes a non-porous element 710. In this embodiment, non-porous element 710 is a metallic ring-shaped element.

[0112] In the embodiment of Figure 6, the first porous element 704a is a disk-shaped element attached to the center of a ring-shaped non-porous element 710. In the embodiment of Figure 6, the second porous element 704b is sandwiched between two actuators 702 and is also attached to the outer surface of the non-porous element 710.

[0113] The piezoelectric component 700 of FIG. 6 is assembled by 1) forming a first porous element 704a and a second porous element 704b, 2) forming a non-porous element 710, 3) attaching the first porous element 704a to the plurality of actuators 702, 4) attaching the non-porous element 710 to the first porous element 704a, and 5) attaching the second porous element 704b to the non-porous element 710.

[0114] In this embodiment, both the first porous element 704a and the second porous element 704b are freeze-cast porous elements, each formed as a single piece by a freeze-cast process.

[0115] 6 may be that the shape of the porous elements 704a, 704b can be controlled during the manufacturing process to allow for control of the aerosol that can be produced by the piezoelectric component 700. For example, because aerosol generation is limited to the area of ​​the porous elements 704a, 704b, the direction and volume of the aerosol can be controlled.

[0116] For purposes of this specification and the claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A ± 5%. Within this context, the number A may be considered to include values ​​that are within the typical standard error for measurement of the property that the number A modifies. In some cases, such as when used in the claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. An aerosol-generating article comprising:

1. An atomizer for atomizing a liquid aerosol-forming substrate to generate an aerosol, said atomizer comprising: A piezoelectric component comprising: An actuator; an atomizer comprising a porous element; and a piezoelectric component comprising: the actuator is disposed to vibrate the porous element to generate an aerosol; and An aerosol-generating article wherein the porous element is a freeze-cast porous element.

2. 2. The aerosol-generating article of claim 1, wherein the piezoelectric component comprises a non-porous element attached to the porous element.

3. 3. The aerosol-generating article according to claim 1, wherein the porous element comprises pores having diameters of 30 micrometers or less.

4. 4. The aerosol-generating article of claim 3, wherein the porous element comprises pores having diameters of at least 10 micrometers.

5. 5. An aerosol-generating article according to claim 1, wherein the porous element is provided with a metal coating.

6. 6. The aerosol-generating article of claim 5, wherein the porous element comprises a nickel coating.

7. an aerosol generator; An aerosol generating system comprising the aerosol-generating article according to any one of claims 1 to 6.

Images