aerosol generator

Abstract

An aerosol generator for an aerosol supply device is provided. The aerosol generator comprises an aerosol generating material and a resistance heating layer (40) comprising a resistance heating element (42). The resistance heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol. The resistance heating element is at least a portion of a conductive path between a first type of electrical contact (44) and a second type of electrical contact (46). The resistance heating layer includes a plurality of surface features (43a, 43b, 43c).

Description

Technical Field

[0001] This specification relates to an aerosol generator for an article for an aerosol supply device. This specification also relates to an electric resistance heating device such as an aerosol generator or a consumable of an aerosol generating device, an article for an aerosol supply device, an aerosol supply system, and a method of forming an aerosol generator for an article for an aerosol supply device.

Background Art

[0002] To release compounds without the need for combustion, aerosol generators for use in aerosol generating devices such as e-cigarettes have been developed. Some exemplary aerosol generating devices include a resistance heater for use in generating an aerosol. Further development of such devices is still needed.

Summary of the Invention

[0003] The scope of protection required in various embodiments of the present invention is described in the independent claims. Embodiments and features described in this specification that do not fall within the scope of the independent claims, if any, should be construed as useful examples for understanding the various embodiments of the present invention.

[0004] According to one aspect, there is provided an aerosol generator for an article for an aerosol supply device, comprising an aerosol generating material and a resistive heating layer comprising a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol, wherein the resistive heating element is at least a portion of a conductive path between a first type of electrical contact and a second type of electrical contact, and the resistive heating layer comprises a plurality of surface features.

[0005] In any one of the above embodiments, the aerosol generating material is located in the resistive heating layer.

[0006] In any one embodiment described above, the multiple surface features include multiple perforations.

[0007] In any one embodiment described above, the plurality of surface features include at least one of a plurality of recesses and a plurality of protrusions.

[0008] In any one embodiment described above, at least some of the surface features are formed along the conductive path.

[0009] In any one embodiment described above, a plurality of surface features are configured to at least partially determine the electrical resistance along the conductive path.

[0010] In any one embodiment described above, an array of surface features is included.

[0011] In any of the embodiments described above, the surface features are regularly spaced apart in the array of surface features.

[0012] In any one embodiment described above, the aerosol generator comprises an aerosol generating layer containing an aerosol generating material.

[0013] In any one embodiment described above, the aerosol generation layer includes a plurality of aerosol generation layer perforations.

[0014] In any one embodiment described above, multiple surface features of the resistance heating layer are aligned with multiple aerosol generation layer perforations.

[0015] In any of the above embodiments, the aerosol-generating layer does not include perforations.

[0016] In any one embodiment described above, a support is provided that is configured to support the resistance heating layer.

[0017] In any one embodiment described above, the support includes a support layer.

[0018] In any one of the above embodiments, the support has electrical insulation properties.

[0019] In any one of the above embodiments, the support includes at least one of paper and cardboard.

[0020] In any one of the above embodiments, the aerosol - generating material is in direct contact with the resistive heating layer. In any one of the above embodiments, the aerosol - generating layer is in direct contact with the resistive heating layer.

[0021] In any one of the above embodiments, the aerosol - generating material is in indirect contact with the resistive heating layer. In any one of the above embodiments, the aerosol - generating layer is in indirect contact with the resistive heating layer.

[0022] In any one of the above embodiments, the resistive heating layer and the support layer define a substrate.

[0023] In any one of the above embodiments, the aerosol generator comprises a laminate including a resistive heating layer and a support layer.

[0024] In any one of the above embodiments, the laminate includes an aerosol - generating layer.

[0025] In any one of the above embodiments, the support layer includes a cardboard layer.

[0026] In any one of the above embodiments, the support does not include perforations. In any one of the above embodiments, the support includes a plurality of support perforations.

[0027] In any one of the above embodiments, a plurality of surface features of the resistive heating layer are aligned with a plurality of support perforations.

[0028] In any one of the above embodiments, the aerosol - generating material forms a physical bond with the support.

[0029] In any one of the above embodiments, the resistive heating layer is sandwiched between the support and the aerosol-forming material. In any one of the above embodiments, the resistive heating layer is sandwiched between the support and the aerosol-forming layer.

[0030] In any one of the above embodiments, the exterior of the article has a length, a width orthogonal to the length, and a depth orthogonal to each of the length and the width, the length being greater than or equal to the width, and the width being greater than the depth.

[0031] In any one of the above embodiments, the aerosol-forming layer is a continuous aerosol-forming layer.

[0032] In any one of the above embodiments, the aerosol-forming layer is a discontinuous aerosol-forming layer.

[0033] In any one of the above embodiments, the aerosol-forming layer includes a plurality of individual aerosol-forming portions.

[0034] In any one of the above embodiments, the resistive heating layer forms a first type of electrical contact.

[0035] In any one of the above embodiments, the resistive heating layer forms a second type of electrical contact.

[0036] In any one of the above embodiments, the aerosol generator comprises a first type of electrical track extending from the heating element and including a first type of electrical contact.

[0037] In any one of the above embodiments, the first type of electrical contact is configured to be electrically connected to a device electrical connector.

[0038] In any one of the above embodiments, the aerosol generator comprises a second type of electrical track extending from the heating element and including a second type of electrical contact.

[0039] In any of the embodiments described above, the second type of electrical contact is configured to be electrically connected to the device electrical connector.

[0040] In any of the above embodiments, the resistance heating element is one of a plurality of resistance heating elements.

[0041] In any of the above embodiments, the resistance heating layer comprises a plurality of heating elements, each resistance heating element being at least a portion of a conductive path between a first type of electrical contact and a second type of electrical contact.

[0042] In any one embodiment described above, each resistance heating element includes a plurality of surface features.

[0043] In any one embodiment described above, each resistive heating element has the same electrical resistance.

[0044] In any one embodiment described above, at least one resistive heating element has a different electrical resistance from another of the resistive heating elements. In any one embodiment described above, each resistive heating element has the same plurality of surface features.

[0045] In any one embodiment described above, at least one resistance heating element has multiple surface features that are different from another of the resistance heating elements.

[0046] In any one embodiment described above, the surface features of at least one of the resistive heating elements have at least one of the size, number, and distribution of surface features that are different from those of another of the resistive heating elements.

[0047] In any one embodiment described above, the first type of electrical contact and the second type of electrical contact allow current to be supplied individually to each of the multiple heating elements.

[0048] In any one embodiment described above, one of the individual aerosol-generating portions is associated with a corresponding one of a plurality of resistance heating elements. In any one embodiment described above, the aerosol-generating layer includes at least one of dots, strips (bands), and patches.

[0049] In any of the above embodiments, the resistance heating element is the first heating element, the resistance heating layer forms the second resistance heating element, and each resistance heating element provides a conductive path for resistively heating a portion of the aerosol generating material to generate an aerosol in each portion of the aerosol generating material.

[0050] In any one embodiment described above, the resistance heating layer forms an array of resistance heating elements, which includes at least a first resistance heating element and a second resistance heating element.

[0051] In any one embodiment described above, each of the first type of electrical contact and the second type of electrical contact is configured to allow current to be supplied individually to each of the resistance heating elements.

[0052] In any one embodiment described above, the aerosol generating layer comprises a film or gel layer containing an aerosol generating material.

[0053] In any one embodiment described above, the aerosol generator comprises a plurality of first-type electrical contacts, and each of the heating elements includes a separate first-type electrical contact.

[0054] In any one embodiment described above, the aerosol generator comprises a plurality of second-type electrical contacts, and each of the resistance heating elements includes a separate second-type electrical contact.

[0055] In any one embodiment described above, the aerosol generator includes a single second type of electrical contact.

[0056] In any of the embodiments described above, a single second type of electrical contact is shared between each of the resistance heating elements.

[0057] In any one embodiment described above, the resistance heating element is formed by at least one of the following: cutting a resistance heating layer, chemically etching a resistance heating layer, forming or pressing a resistance heating layer onto a substrate, and printing a resistance heating layer.

[0058] In any of the above embodiments, the resistance heating layer is in the form of a foil.

[0059] According to one embodiment, an aerosol generator is provided, comprising an aerosolizable layer incorporating an aerosolizable material and a conductive layer in contact with the aerosolizable layer, wherein the conductive layer includes a plurality of perforations, and the conductive layer comprises one or more heating elements, the heating element or each heating element providing a conductive path for resistance heating of a portion of the aerosolizable material to generate an aerosol, and the heating element or each heating element extending from a first type of electrical connection to a second type of electrical connection. The aerosolizable layer may include a membrane or gel incorporating the aerosolizable material.

[0060] In any one embodiment described above, a conductive layer is formed on the one or more heating elements. In any one embodiment described above, the conductive layer may be formed on multiple heating elements, each heating element providing a conductive path for resistance heating of a portion of the aerosolizable material to generate vapor in each portion of the support.

[0061] In any of the above embodiments, the electrical connection may allow current to be supplied individually to each of the multiple heating elements (e.g., multiple positive electrical connections). In any of the above embodiments, each of the heating elements may have a separate electrical connection of the first type. In any of the above embodiments, the aerosol generator comprises a second type of multiple electrical connections (e.g., negative electrical connections). In any of the above embodiments, the aerosol generator comprises a second type of single connection (e.g., a single negative electrical connection).

[0062] In any one embodiment above, instead of using a common connection of the second type, separate connections of the first and second types are provided for each heating section. In any one embodiment above, the first type of electrical connection is located at the first edge of the conductive layer, and the second type of electrical connection is located at the second edge of the conductive layer. In any one embodiment above, the first and second types of electrical connections may be located on both sides of the area where the heating element is provided. In any one embodiment above, some or all of the first and second types of electrical connections are located at the same edge of the conductive layer or on the second side of the area where the heating element is provided.

[0063] In any of the above embodiments, the heating element may be formed by cutting the conductive layer (for example, using a laser cutter).

[0064] In any of the above embodiments, the heating element may be formed by one or more of the following: chemical etching of the conductive layer, forming or pressing a conductive layer onto a substrate, and printing the conductive layer.

[0065] In any of the above embodiments, each heating element includes a nonlinear conductive path (e.g., a winding or meandering path) between a first electrical connection and a second electrical connection. In any of the above embodiments, the aerosolizable material includes a plurality of perforations. In any of the above embodiments, each heating element is a linear heating element including a conductive path extending in the longitudinal direction of the aerosolizable layer. In any of the above embodiments, the conductive layer may be in the form of a foil. In any of the above embodiments, the conductive layer may be a metal layer (e.g., a metal foil such as aluminum foil).

[0066] According to one embodiment, an article is provided that can be equipped with an aerosol generator according to one embodiment of any of the above embodiments.

[0067] In any of the above embodiments, the article is a consumable for the aerosol generation system.

[0068] According to one embodiment, an aerosol supply device is provided that is configured to receive an aerosol generator according to any one embodiment described above.

[0069] According to one embodiment, an aerosol supply system is provided comprising an aerosol generator according to any one embodiment described above, and an aerosol supply device configured to receive the aerosol generator or an article.

[0070] According to one embodiment, a blank for forming an aerosol generator of an article for an aerosol supply device is provided, comprising a resistive heating layer, which forms a heating element and provides a conductive path for resistive heating, a first type of electrical contact, and a second type of electrical contact, wherein the heating element extends between the first type of electrical contact and the second type of electrical contact, and the resistive heating layer includes a plurality of surface features.

[0071] In any one embodiment described above, the multiple surface features include multiple perforations.

[0072] According to one embodiment, a method is provided comprising the steps of forming a resistance heating layer having a resistance heating element, forming an aerosol generating layer containing an aerosol generating material on the resistance heating layer, wherein the resistance heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol, and the resistance heating element is at least a portion of a conductive path between a first type of electrical contact and a second type of electrical contact, and forming a plurality of surface features on the resistance heating layer.

[0073] According to one embodiment, a method is provided comprising the steps of forming a resistance heating layer having resistance heating elements, arranging an aerosol generating material in the resistance heating layer, wherein the resistance heating elements are configured to heat at least a portion of the aerosol generating material to generate an aerosol, and the resistance heating elements are at least a portion of a conductive path between a first type of electrical contact and a second type of electrical contact, and forming a plurality of surface features in the resistance heating layer.

[0074] In any one embodiment described above, the multiple surface features include multiple perforations.

[0075] According to one embodiment, a method is provided comprising the steps of forming a conductive layer on one or more heating elements, wherein the heating element or each heating element provides a conductive path for resistance heating of a portion of an aerosolizable material to generate an aerosol; and contacting the formed conductive layer with an aerosolizable layer, wherein the aerosolizable layer incorporates the aerosolizable material. The heating element or each heating element extends from a first type of electrical connection to a second type of electrical connection. The conductive layer includes a plurality of perforations. The aerosolizable layer may include a membrane or gel incorporating the aerosolizable material.

[0076] In any one embodiment above, the step of forming the conductive layer may include forming the perforations. In any one embodiment above, the method includes the step of forming the perforations in the conductive layer before bringing the formed conductive layer into contact with the aerosolizable layer. In any one embodiment above, the method includes the step of forming the perforations in the conductive layer after bringing the formed conductive layer into contact with the aerosolizable layer. In any one embodiment above, the method includes the step of forming perforations in the aerosolizable material. In any one embodiment above, the conductive layer is formed on a plurality of heating elements, each heating element providing a conductive path for resistance heating of a portion of the aerosolizable material to generate an aerosol in each portion of the aerosolizable layer. In any one embodiment above, electrical connections may allow current to be supplied individually to each of the plurality of heating elements. In any one embodiment above, the method includes the step of forming the heating elements by cutting the conductive layer at least partially (for example, using a laser cutter). In any one embodiment above, the method includes the step of forming the heating elements by chemically etching the conductive layer at least partially. In any one embodiment described above, the method includes the step of forming the heating element by printing the conductive layer at least partially. In any one embodiment described above, each heating element includes a nonlinear conductive path (e.g., a winding or meandering path) between a first electrical connection and a second electrical connection.

[0077] In one embodiment, an article is provided comprising an aerosol generator described in any of the above or formed by any of the above methods. The article may be a consumable of the aerosol generation system.

[0078] According to one embodiment, a non-flammable aerosol generating device is provided that is configured to receive an aerosol generator, article, or consumable formed by any of the methods described above.

[0079] According to one embodiment, a system is provided comprising any of the above-described non-flammable aerosol generating devices and an aerosol generator, article, or consumable formed according to any of the above-described methods. The aerosol generator, article, or consumable may further comprise any of the above-described devices.

[0080] In one embodiment, a component kit is provided comprising a non-flammable aerosol generating device of the fourth embodiment and an aerosol generator, article, or consumable formed as described in any of the above or by any of the above methods, wherein the aerosol generator is detachable from the non-flammable aerosol generating device. The component kit may further comprise the apparatus described in any of the above. The non-flammable aerosol generating device may include an integrated battery.

[0081] Exemplary embodiments are described below, for illustrative purposes only, with reference to the following schematic drawings. [Brief explanation of the drawing]

[0082] [Figure 1] This is a block diagram of the aerosol supply system. [Figure 2] This is a block diagram of the aerosol generator. [Figure 3] This is a block diagram of the aerosol generator. [Figure 4] This is a diagram showing the conductive layer. [Figure 5] This is a diagram showing the conductive layer. [Figure 6] This is a diagram showing the heating element. [Figure 7] This is a diagram showing the conductive layer. [Figure 8] This is a diagram showing the conductive layer. [Figure 9] This is a diagram showing the conductive layer. [Figure 10] This is a flowchart illustrating the algorithm. [Figure 11] This is a flowchart illustrating the algorithm. [Figure 12] This is a flowchart illustrating the algorithm. [Figure 13] This is a flowchart illustrating the algorithm. [Figure 14] This diagram shows the formation of an aerosol generator. [Figure 15] This figure shows where the conductive layer is formed. [Figure 16] This is a flowchart illustrating the algorithm. [Figure 17] This is a flowchart illustrating the algorithm. [Figure 18] This is a flowchart illustrating the algorithm. [Figure 19] This is a diagram showing the conductive layer. [Figure 20] This is a diagram showing the conductive layer. [Figure 21] This is a diagram showing a part of an aerosol generator. [Figure 22] This figure shows connectors used in several embodiments. [Figure 23] This is a block diagram of the aerosol generation system. [Modes for carrying out the invention]

[0083] In this specification, the term “delivery mechanism” is intended to encompass a system for delivering a substance to a user. Non-flammable aerosol supply systems that release compounds from aerosolizable materials without burning the aerosolizable materials, such as hybrid systems for generating aerosols using a combination of e-cigarettes, tobacco heating products, and aerosolizable materials, and Includes articles containing aerosolizable materials and configured for use in one of these non-flammable aerosol supply systems.

[0084] According to this disclosure, a “non-flammable” aerosol supply system is a system in which the component aerosol-generating materials of the aerosol supply system (or its components) are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0085] In some embodiments, the delivery system is a non-flammable aerosol supply system, such as a powered non-flammable aerosol supply system.

[0086] In some embodiments, the non-flammable aerosol supply system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0087] In some embodiments, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0088] In some embodiments, the non-flammable aerosol supply system is a hybrid system for generating 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 the form of a solid, liquid, or gel, 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.

[0089] Typically, a non-flammable aerosol supply system may comprise a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device.

[0090] In some embodiments, the disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-flammable aerosol supply devices. Throughout the disclosure, these consumables may also be referred to as articles.

[0091] In some embodiments, the non-flammable aerosol supply system, such as the non-flammable aerosol supply device, may include a power source and a controller. The power source may be, for example, a power supply or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be activated to disperse a force in the form of heat to an aerosol-generating material or heat-transferring material adjacent to the heat-generating power source.

[0092] In some embodiments, the non-flammable aerosol supply system may include consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an area for receiving aerosol modifiers.

[0093] In some embodiments, consumables for use with a non-flammable aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a roll of paper, a filter, a mouthpiece, and / or an aerosol corrector.

[0094] In some embodiments, the substance to be delivered may be an aerosol-forming material or a material not intended to be aerosolized. Where appropriate, the material may include one or more active ingredients, one or more fragrances, one or more aerosol-forming materials, and / or one or more other functional materials.

[0095] In some embodiments, the substance to be delivered includes an active substance (sometimes referred to herein as an active compound).

[0096] In this specification, the active substance may be a physiologically active material, which is a material intended to produce or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, psychotropic drugs, or digiceutical or other technical / electronic devices capable of inducing a physiological response, such as vagus nerve stimulation (VGS). The active substance may be of natural origin or obtained synthetically. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant substances. In one embodiment, the active substance is a legally permissible recreational drug.

[0097] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0098] As described herein, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0099] As described herein, the active substance may include, or be derived from, one or more plant substances, or components, derivatives, or extracts thereof. In this specification, the term “plant substance” includes, but is not limited to, any material derived from plants, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, pods, etc. Alternatively, the material may include synthetically obtained active compounds naturally present in plant substances. The material may be in the form of a liquid, gas, solid, powder, fine powder, granules, pellets, fragments, shards, or sheets. Examples of plant-based substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (green or black), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. Examples include dar, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following varieties: Mentha Arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0100] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components, derivatives, or extracts thereof, where the plant substance is tobacco.

[0101] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components, derivatives, or extracts thereof, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0102] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components, derivatives, or extracts thereof, the plant substances being selected from rooibos and fennel.

[0103] In some embodiments, the substance to be delivered includes a fragrance.

[0104] In this specification, the terms “flavoring” and “flavoring” refer to materials that may be used in products intended for adult consumers to produce a desired taste, aroma, or other somatic sensation, where permitted by local regulations.The fragrances are derived from natural fragrance materials, plant substances, plant substance extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits, papaya). A, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, Fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the Mentha genus, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay laurel, mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, turmeric, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, The fragrance may also contain other additives such as marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant substances, or breath fresheners. The fragrance may be an imitation, synthetic or natural ingredient, or a mixture thereof.The fragrance may be in any preferred form, such as a liquid like an oil, a solid like a powder, or a gas.

[0105] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus fruit, and / or red berry flavoring components. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring components extracted from tobacco. In some embodiments, the flavoring includes flavoring components extracted from cannabis.

[0106] In some embodiments, the fragrance may include, in addition to or instead of, olfactory or gustatory nerves, sensations intended to be chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), and these may include active ingredients that provide heating, cooling, tingling, or numbing effects. Preferred thermal agents may be, but are not limited to, vanillyl ethyl ether, and preferred cooling agents may be, but are not limited to, eucalyptol or WS-3.

[0107] Aerosolizable materials, sometimes referred to herein as aerosol-generating materials, are materials capable of generating aerosols when activated, for example, by heating, irradiation, or any other method. Aerosolizable materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine and / or flavorings.

[0108] Aerosol-generating materials (sometimes referred to herein as aerosolizable materials) are materials capable of generating aerosols when activated, for example, by heating, irradiation, or any other method. Aerosol-generating materials may be in the form of, for example, a solid, a liquid, or a semi-solid (such as a gel), and may or may not contain active substances and / or flavorings.

[0109] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0110] The aerosol-generating material may include adhesives such as gelling agents and aerosol-forming agents. Optionally, there may be a substance to be delivered and / or fillers. Optionally, there may also be a solvent such as water, 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-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0111] The aerosol-generating material may include an aerosol-generating film, or may be in the form of an aerosol-generating film. The aerosol-generating film may include an adhesive such as a gelling agent and an aerosol-forming agent. Optionally, there may be a substance to be delivered and / or a filler. The aerosol-generating film may not substantially contain plant-derived material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco-free.

[0112] The aerosol-generating film may have a thickness of approximately 0.015 mm to approximately 1 mm. For example, the thickness may be in the range of approximately 0.05 mm, 0.1 mm, or 0.15 mm to approximately 0.5 mm or 0.3 mm.

[0113] The aerosol-generating film may be continuous. For example, the film may contain continuous thin sheet material, or may consist of continuous thin sheet material.

[0114] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more separate parts or regions of the aerosol-generating material, such as dots, flakes, or lines, which may be supported by a support. In such embodiments, the support may be planar or non-planar.

[0115] The aerosol-generating film may be formed by combining an adhesive such as a gelling agent with one or more other components such as a solvent such as water, an aerosol-forming agent, and one or more substances to be delivered to form a slurry, and then heating the slurry to volatilize at least some of the solvent to form the aerosol-generating film.

[0116] The slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0117] The aerosol-generating material may be an "amorphous solid." In some embodiments, the amorphous solid is a "monolithic solid." The aerosol-generating material may be non-fibrous or fibrous. In some embodiments, the aerosol-generating material may be a dry gel. The aerosol-generating material may be a solid material that can hold some fluid, such as a liquid, internally. In some embodiments, the held fluid may be water (such as water absorbed from the surroundings of the aerosol-generating material), or the held fluid may be a solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water.

[0118] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0119] The aerosol-forming material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may contain one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetins, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0120] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, adhesives, fillers, stabilizers, and / or antioxidants.

[0121] The material may be present on or within a support to form a substrate. The support may be, for example, paper, cardboard, paperboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may include these. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded in the material. In some alternative embodiments, the susceptor is located on one or both sides of the material.

[0122] Consumables are articles containing or consisting of aerosol-generating material, which are intended to be consumed in part or in whole during use by the user. Consumables may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a roll of paper, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater, which releases heat during use to generate an aerosol in the aerosol-generating material. The heater may comprise, for example, a flammable material, a material that can be heated by electrical conductivity, or a susceptor.

[0123] An aerosol supply device may receive an article containing an aerosol-generating material for heating. In this context, “article” is a component containing or having an aerosol-generating material in use, which, when heated, volatilizes the aerosol-generating material in use and optionally other components. A user may insert an article into or onto the aerosol supply device, heat the article to generate an aerosol, and then inhale the aerosol.

[0124] An 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 apply thermal energy to the aerosol-generating material, thereby releasing one or more volatile substances from the material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to apply one or more of the following to the aerosol-generating material: vibration, rising pressure, or electrostatic energy.

[0125] Figure 1 is a block diagram of an aerosol generating device, shown as a whole by reference numeral 10, according to an exemplary embodiment.

[0126] The aerosol generation device 10 comprises a battery 11 (e.g., a rechargeable battery), a control circuit 12, and an aerosol generator 13. As will be discussed in detail below, the aerosol generator 13 includes a resistance heater for heating an aerosolizable material (e.g., a membrane or gel) to generate an aerosol (e.g., vapor). The aerosolizable material is sometimes called an aerosol-generating material.

[0127] The aerosol generation device 10 forms an aerosol supply system comprising an aerosol supply device and an article equipped with an aerosol generator 13. The resistance heater comprises at least one resistance heating element.

[0128] Battery 11 acts as a power source. The control circuit acts as a controller and includes a processor and memory. The control circuit is configured to implement the above method or the methods described later.

[0129] When using device 10, air is drawn into the air inlet of the aerosol generator 13, as indicated by arrow 16. The aerosol generated by the aerosol generator 13 exits the device through the air outlet (for example, into the mouth of the user of device 10), as indicated by arrow 17.

[0130] In some exemplary embodiments, the aerosol generating device 10 comprises two main components: a control section 2 (sometimes referred to as a reusable section) and consumables 4 (sometimes referred to as replaceable or disposable cartridges). When the aerosol generating device 10 is in use, the control section 2 and consumables 4 may be releasably connected at an interface 6. The consumables 4 may be removable and replaceable (for example, when the consumables are used), and the control section 2 may be reused with different consumables.

[0131] The aerosol generation device 10, also called an aerosol supply system, comprises a control section 2, sometimes referred to as the aerosol supply device 10, and consumables 4, sometimes referred to as articles 4.

[0132] The aerosol generator 13 forms part of article 4. The aerosol generator 13 includes a resistance heating component configured to generate an aerosol by heating at least one of an aerosol generating material, such as a membrane and / or a gel.

[0133] In the embodiments described above, or each heating element, is a resistance heating element, as will be described in detail below. In such a configuration, the system comprises a resistance heating generator which includes components for heating a heating component via a resistance heating process. In this case, an electric current is applied directly to the resistance heating element, and the resulting flow of current in the heating element acts as a heating component, heating the heating element by Joule heating. The resistance heating element includes a resistive material configured to generate heat when a suitable current passes through it, and the heating component includes electrical contacts for supplying current to the resistive material. Providing a resistance heating component enables a compact configuration. Resistance heating provides an efficient configuration.

[0134] A "section" is sometimes called a "part." A "part" is sometimes called a "section." Consumables are sometimes called replaceable or disposable items.

[0135] Naturally, the aerosol generating device 10 is provided only as an example and is highly schematic. Many alternative aerosol generating devices and other devices may be used in exemplary implementations of the principles described herein. For example, in some exemplary embodiments, air is drawn in through an air inlet in the control section 2, passes through interface 6, and exits consumable 4.

[0136] The aerosol generator 13 is configured to generate an aerosol from an aerosol-generating material, also known as an aerosolizable material, during the operation of the aerosol supply system, as will be described in detail below. The aerosol supply system 10 is elongated and extends along its longitudinal axis. The aerosol supply system 10 has a proximal end that is closest to the user (e.g., the user's mouth) when used by the user to inhale the aerosol generated by the aerosol supply system, and a distal end that is furthest from the user during use. The proximal end is sometimes called the “mouthpiece end.” The aerosol supply system accordingly defines a proximal direction that is directed toward the user during use. Furthermore, the aerosol supply system 10 similarly defines a distal direction that is directed away from the user during use. The terms “proximal” and “distal” are explained by referring to the relative positioning of such features relative to each other in the proximal-distal direction along the longitudinal axis when applied to features of the system 10.

[0137] In this embodiment, the aerosol generator 13 may be fully or partially inserted into the aerosol supply device 10. The configuration of the aerosol supply device 10 may vary, for example, the opening may be located within the longitudinal side wall of the aerosol supply device 10 and / or may be closed by another feature of the aerosol supply device 10 during use. In this configuration, article 4 defines a mouthpiece at its proximal end. In this embodiment, the aerosol supply device 10 defines a mouthpiece. During use, the user places their mouth over the mouthpiece.

[0138] Figure 2 is a block diagram of an aerosol generator, shown as a whole by reference numeral 20, according to an exemplary embodiment. The aerosol generator 20 is an exemplary implementation of the aerosol generator 13 of the aerosol generating device 10 described above.

[0139] The aerosol generator 20 comprises an aerosolizable layer 22 (incorporating an aerosolizable material) and a conductive layer 24 in contact with the aerosolizable layer. As will be described in detail below, the conductive layer 24 is formed on one or more heating elements, each heating element providing a conductive path for resistance heating of a portion of the aerosolizable material in the aerosolizable layer 22 to generate an aerosol. The aerosolizable material may be, for example, in the form of a film or a gel.

[0140] The aerosolizable layer 22, also known as the aerosol-generating layer 22, contains an aerosolizable material also known as an aerosol-generating material.

[0141] The conductive layer 24 is formed as a resistive heating layer. The resistive heating layer contains a material that can be resistively heated in response to an electric current being passed through it.

[0142] The aerosol generator 20 includes a resistance heating layer 24. The aerosol generating layer 22 is located on the resistance heating layer 24. The aerosol generating layer 22 is in direct contact with the resistance heating layer 24. In embodiments, the aerosol generating layer 22 is in indirect contact with the resistance heating layer 24. In embodiments, the resistance heating layer 24 may have a coating. The coating of the resistance heating layer 24 may be located on a conductive material.

[0143] The conductive layer 24 may take the form of a metal layer such as an aluminum layer, or a non-metallic material (such as graphene). The conductive layer may also take the form of a foil (for example, aluminum foil).

[0144] The aerosol generator 20 is configured to generate aerosols from aerosol-generating material when the aerosol supply system 10 is in operation, as will be described in detail below.

[0145] Figure 3 is a block diagram of an aerosol generator, shown as a whole by reference numeral 30, according to an exemplary embodiment. The aerosol generator 30 is an exemplary implementation of the aerosol generator 13 described above.

[0146] The aerosol generator 30 comprises the aerosolizable layer 22 and the conductive layer 24 described above. The aerosol generator 30 further comprises a support (or substrate) 32. The support 32 may include paper or cardboard material that provides structural support for the aerosol generator 30. As shown in Figure 3, in the aerosol generator 30, the conductive layer 24 is sandwiched between the support 32 and the aerosolizable layer 22.

[0147] In the embodiments described herein, the support 32 may be configured as a support layer. The support 32 may be electrically insulating. The support 32 may include at least one of paper and cardboard. In the embodiments, the aerosolizable layer 22 is in direct contact with the conductive layer 24. The aerosolizable layer 22 may be in indirect contact with the conductive layer 24. The conductive layer 24 and the support layer define the substrate. The substrate 32 supports the aerosolizing layer 22. The support layer comprises a cardboard layer. The support 32 does not contain perforations.

[0148] In an embodiment, the aerosol generator 30 may comprise a laminate comprising a conductive layer 24 and a support layer 32. In an embodiment, the laminate comprises an aerosolizable layer 22. The aerosolizable layer 22 may be formed as a continuous structure or from individual parts. The individual parts may include one or more of dots, flakes, helices, or other shapes. In an embodiment, the individual parts are aligned with a heating element.

[0149] One or more of the aerosolizable layer 22, the conductive layer 24, and the support layer 32 may comprise further layers. For example, the support layer 32 may comprise a backing layer or an intermediate layer. In this embodiment, the support layer 32 is omitted.

[0150] The above-described aerosol generators 30 are formed in a stacked configuration. In embodiments, other configurations such as tubular structures of articles are also conceivable. In such tubular structures, the aerosol generators 30 define a tubular configuration. The tubular shape may include a circular cross-section and other polygonal shapes.

[0151] In this embodiment, as shown in the figure, article 30 has a flat configuration. That is, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and width, where the length is greater than or equal to the width, and the width is greater than the depth. Other configurations are also conceivable.

[0152] Figure 4 shows a conductive layer, collectively referred to as reference numeral 40, according to an exemplary embodiment. The conductive layer 40 comprises a heating element 42, a first electrical connection 44, and a second electrical connection 46. In some exemplary embodiments, the first electrical connection 44 provides a positive connection and the second electrical connection 46 provides a negative connection, so that current flows through the heating element 42 and between the electrical connections. As shown in Figure 4, the heating element 42 includes a plurality of perforations (including perforations 43a, 43b, 43c, etc.).

[0153] Multiple perforations act as surface features. In embodiments, the surface features include at least one of projections, recesses, indentations, depressions, holes, perforations, gaps, etc. The surface features may also be localized distortions or formations of the layer, so that at least one of the volumes of material in the thickness and / or width of the heating element at one or more specific locations along the heating element is different from the volume of material in the thickness and / or width of the heating element at one or more other specific locations along the heating element. The embodiments described herein describe multiple perforations for illustrative purposes, but it will be understood by those skilled in the art that multiple projections may be any surface features.

[0154] The electrical resistance of the heating element 42 may depend on the nature of the perforations in the conductive layer (e.g., the size, number, and distribution of the perforations). Therefore, the perforated conductive layer may have a higher electrical resistance than a straight, unperforated path between the first and second electrical connectors.

[0155] The conductive layer 40 can be used as the conductive layer 24 of the aerosol generator 20 or 30 (or any similar aerosol generator), and thus the conductive path of the heating element 42 can be used to generate an aerosol by resistively heating a portion of the aerosolizable material.

[0156] Figure 5 shows a conductive layer, collectively referred to as reference numeral 50, according to an exemplary embodiment. The conductive layer 50 comprises a first heating element 52a, a second heating element 52b, first electrical connections 54a and 54b, and a second electrical connection 56. In some exemplary embodiments, each of the first electrical connections 54a and 54b provides a positive connection, and therefore the second electrical connection 56 provides a negative connection, so that current flows through the heating elements 52s and 52b and between the electrical connections.

[0157] The number of electrical connections, sometimes called electrical contacts, may vary. Thus, each heating element 52a, 52b extends between individual first-type electrical contacts 54a, 54b and a common second-type electrical contact 56.

[0158] As shown in Figure 5, the heating elements 52a and 52b are provided with a plurality of perforations (including perforations 53a, 53b, 53c, etc.). The two heating elements are formed by a cut 58 in the conductive layer that separates the first and second heating elements. The cut 58 may be generated by laser cutting or some similar process (discussed further below).

[0159] The perforations are located in the conductive layer 40. In the embodiment, at least some of the multiple perforations are formed along the conductive path. The multiple perforations may affect the electrical properties of the conductive path. In the embodiment, the multiple surface features are configured to at least partially determine the electrical resistance along the conductive path. In the embodiment, the multiple surface features are configured to not affect the electrical resistance along the conductive path, or to minimize the effect on the electrical resistance along the conductive path.

[0160] The perforations may be arranged on the heating element in various configurations. The heating element may include an array of perforations. The heating element may include multiple arrays of perforations. The perforations may be regularly spaced in the array of perforations. In various embodiments, many variations of the distribution of perforations are conceivable. The perforations may be distributed in parallel rows, parallel columns, regularly, irregularly, randomly, etc.

[0161] In embodiments, the aerosolizable layer 22 may include a plurality of aerosol-generating layer perforations. The plurality of perforations in the conductive layer are aligned with the plurality of aerosol-generating layer perforations. This can be advantageous as it allows for further gas flow, as will be described below. Furthermore, it can be made easier to monitor quality control during the manufacturing of the conductive layer and the aerosolizable layer. This can also further reduce the peeling effect, as will be described further below. In embodiments, many variations of the perforation distribution are envisioned, including any one of parallel rows, parallel columns, regular, irregular, random, etc. The aerosol-generating layer may also not include perforations.

[0162] In the embodiment, the conductive layer 24 includes a plurality of support perforations. The support perforations are perforations configured to correspond to the surface features of the support. The plurality of surface features of the conductive layer are aligned with the plurality of support perforations. The support perforations of the conductive layer 24 can help to position the conductive layer on the support. In the embodiment, the aerosolizable layer 22 forms a physical bond with the support 32. The conductive layer is sandwiched between the support 32 and the aerosolizable layer 22.

[0163] The conductive layer 50 may also be used as the conductive layer 24 of the aerosol generator 20 or 30 (or some similar aerosol generator), and thus the conductive paths of the heating elements 52a and 52b can be used to resistively heat a portion of the aerosolizable material to generate an aerosol. Furthermore, by providing separate first electrical connections 54a and 54b, the heating elements 52a and 52b can be individually controlled to control the generation of aerosols from different portions of the aerosolizable material.

[0164] In the embodiment, the aerosol-generating layer 22 is a continuous aerosol-generating layer. In the embodiment, the aerosol-generating layer 22 is a discontinuous aerosol-generating layer. In the embodiment, the aerosol-generating layer includes a plurality of separate aerosol-generating portions. Each of the heating elements may heat the corresponding separate portion of the aerosolizable layer. It is advantageous that each separate portion can be configured to provide a different experience to the user after the aerosol has been generated.

[0165] Figure 6 shows a heating element, collectively referred to as reference number 60, according to an exemplary embodiment. One or more heating elements 60 may be formed from the conductive layer 24 described above.

[0166] The heating element 60 has a non-linear conductive path between the first electrical connection 62 and the second electrical connector 63. In some exemplary embodiments, the first electrical connection 62 provides a positive connection and the second electrical connection 63 provides a negative connection, so that current flows between the electrical connections through this path. The winding nature of the path in the heating element 60 increases the overall length of the path between the first and second electrical connectors, and therefore increases the electrical resistance of the path (compared to a straight, direct path between the first and second electrical connectors).

[0167] In the embodiment, the conductive layer 24 includes a first type of electrical track 64 extending from the heating element 62. The first type of electrical track 64 includes a first type of electrical connection 62. The first type of electrical contact 62 is configured to electrically connect to a device electrical connector. The first type of electrical contact 62 includes a first type of exposed contact area. The first type of exposed contact area is exposed on the article to connect directly to the device electrical connector.

[0168] In the embodiment, the conductive layer 24 includes a second type of electrical track 65 extending from the heating element 60. The second type of electrical track 65 includes a second type of electrical connection 63. The second type of electrical connection 63 is configured to electrically connect to a device electrical connector. The second type of electrical contact 63 includes a second type of exposed contact area. The second type of exposed contact area is exposed on the article to connect directly to the device electrical connector.

[0169] As will be discussed in detail below, the conduction path of the heating element 60 may be fabricated by forming tracks within the heating element, for example, by cutting tracks into the conductive layer constituting the heating element. In some exemplary embodiments, the tracks may have a width in the range of 0.5 mm to 1 mm (two exemplary prototypes have widths of 0.93 mm and 0.72 mm, respectively) and gaps between tracks of less than approximately 0.25 mm (the same two exemplary prototypes have gaps of 0.2 mm and 0.05 mm, respectively). The heating element may have overall dimensions of approximately 10 mm × 10 mm. Naturally, other dimensions are possible in other exemplary embodiments. By forming heating elements of these dimensions from aluminum foil with a thickness of 0.006 mm and an electrical resistivity of 2 to 6 μΩ cm, the resistance of the path is calculated to be approximately 1 Ω. In one exemplary embodiment, resistances of 0.83 to 1.31 Ω were measured.

[0170] The resistance heating layer comprises a plurality of resistance heating elements 40. The plurality of heating elements 40 are formed in an array as shown in Figure 5. The array of heating elements may be arranged in a single row. The array of heating elements may be arranged in a single row along the longitudinal axis of the aerosol generator. The array of heating elements may be arranged in a single row across the longitudinal axis of the aerosol generator. Other configurations are also conceivable.

[0171] The resistance heating layer 24 includes a first type of electrical track 44 extending from the resistance heating element 40. The first type of electrical track 44 includes a first type of electrical contact 42. The first type of electrical contact 42 is configured to electrically connect to a device electrical connector. The first type of electrical contact 42 includes a first type of exposed contact area. The first type of exposed contact area is exposed on the article to connect directly to the device electrical connector.

[0172] The resistance heating layer 24 includes a second type of electrical track 45 extending from the resistance heating element 40. The second type of electrical track 45 includes a second type of electrical contact 43. The second type of electrical contact 43 is configured to electrically connect to a device electrical connector. The second type of electrical contact 43 includes a second type of exposed contact area. The second type of exposed contact area is exposed on the article to connect directly to the device electrical connector.

[0173] In embodiments, the conduction path of the heating element is created by defining at least one electrical insulation barrier within the resistive heating layer 24. In embodiments, the electrical insulation barrier is formed by cutting conductive limitations (i.e., electrical insulating portions), such as gaps, channels, or slots, into a thin sheet formed from a conductive material to form the resistive heating layer 24. In embodiments, the resistive heating layer 24 is pre-formed to define the above or each resistive heating element 40 and then attached to the support 32. In embodiments, the resistive heating layer 24 is attached to the support 32 and then the above or each resistive heating element 40 is defined in the resistive heating layer 24. The above or each resistive heating element 40 defining the resistive heating layer 24 may be a printed heater. At least one electrical insulation barrier defines first and second types of electrical tracks. The electrical insulation barrier defines a barrier to conductivity in this barrier.

[0174] The insulating barrier may be an air gap. In embodiments, the insulating barrier is a filled gap, which is filled with, for example, an insulating material. The barrier defines a barrier to conductivity within this barrier.

[0175] The above-mentioned or each of the resistance heating elements 60 defining the resistance heating layer 24 may be formed by a cutting operation. The cutting may include die cutting. The resistance heating elements may be formed by an operation applied only to the resistance heating layer. In the embodiment, the resistance heating elements may be formed by an operation applied to the resistance heating layer and the support layer, for example, an operation to cut the resistance heating layer and the support layer.

[0176] Figure 7 shows a conductive layer, collectively referred to as reference numeral 70, according to an exemplary embodiment. The conductive layer 70 comprises a heating element 72, a first electrical connection 74 (e.g., a positive connection), and a second electrical connection 76 (e.g., a negative connection). As shown in Figure 6, the heating element 72 includes a plurality of perforations (including perforations 73a, 73b, 73c, etc.).

[0177] The heating element 72 is provided with a non-linear conductive path between the first electrical connection 74 and the second electrical connection 76 (formed by cuts including cuts 78a and 78b in the conductive layer separating the first heating element and the second heating element, and other similar cuts). Similar to the heating element 60 described above, the winding nature of the path in the heating element 72 increases the overall length of the path between the first and second electrical connectors, and therefore increases the electrical resistance of the path (compared to a straight, direct path between the first and second electrical connectors). This increases the electrical resistance in addition to the increase in electrical resistance resulting from the multiple perforations. Therefore, the electrical resistance of the heating element 72 may depend on the length of the conductive path and the nature of the perforations in the conductive layer (e.g., the size, number, and distribution of the perforations).

[0178] In this embodiment, the electrical resistance of each heating element 72 among the multiple heating elements may vary. Each heating element among the multiple heating elements may have the same electrical resistance. At least one resistive heating element among the multiple heating elements may have a different electrical resistance from another resistive heating element. The electrical resistance of each electrical connection of the heating elements may vary. The electrical resistance of each heating element may vary according to the electrical resistance of the associated electrical connection, such that the total electrical resistance of the electrical connection and the heating element is the same for each portion of the conductive layer 24.

[0179] In the embodiment, each heating element has the same plurality of perforations. At least one resistive heating element may have a plurality of perforations different from that of another heating element. A plurality of surface features of at least one heating element have at least one of the sizes, numbers, and distributions of perforations different from that of another heating element. The electrical resistance of the heating elements may be adjusted, configured, or regulated according to the requirements of the heating elements. Heating elements with different electrical resistances can be advantageous because they can provide different heating characteristics, thereby providing a different experience to the user. In one example, the heating elements may be configured to heat a portion of a material which is a different composition from one or more of the other parts. Each heating element may be configured to have a different temperature profile.

[0180] The conductive layer 70 may also be used as the conductive layer 24 of the aerosol generator 20 or 30 (or some similar aerosol generator), and thus the conductive path of the heating element 72 can be used to generate an aerosol by resistively heating the aerosolizable material.

[0181] Figure 8 shows a conductive layer, collectively referred to as reference numeral 80, according to an exemplary embodiment. The conductive layer 80 is an exemplary implementation of the heating element 24 of the aerosol generator 20 or 30 described above.

[0182] The conductive layer 80 is formed on a plurality of heating elements, indicated by reference numbers 81 to 85. Each of the heating elements 81 to 85 has a nonlinear path extending from a first type of electrical connection (connections 86a to 86e, respectively) to a second type of electrical connection (connection 88). Thus, the conductive layer 80 provides a plurality of heating elements similar to the heating elements 60 and 72 described above. Note that the conductive layer 80 may include perforations (not shown) similar to those of the conductive layer 70 described above.

[0183] When layer 80 is used as a heating element 24 of the aerosol generator 20 or 30, each of the heating elements 81 to 85 provides a conductive path for resistance heating of a portion of the aerosolizable material 22 to generate an aerosol in each portion of the support.

[0184] The first type of separate electrical connections 86a-86e allows current to be supplied individually to each of the multiple heating elements 81-85. Thus, heating of different sections of the aerosolizable material can be controlled. For example, the aerosol generator may have five aerosol generating sections. Layer 80 allows each of those sections to be activated separately. Thus, for example, five puffs of aerosol may be generated from a single consumable incorporating the heating elements 81-85.

[0185] Accordingly, for example, five puffs of aerosol may be produced from a single consumable incorporating a single aerosol generator 20 or 30, or ten puffs of aerosol may be produced from a single consumable incorporating two aerosol generators 20 or 30.

[0186] In the exemplary conductive layer 80, a first type of multiple electrical connections 86a-86e (e.g., positive electrical connections) are provided, and a second type of single connection 88 (e.g., negative electrical connection) is provided. This is not necessarily required for all implementations. For example, a second type of multiple connections may also be provided.

[0187] In this embodiment, each resistance heating element 81-85 comprises a corresponding one of the first type of electrical contacts 86a-86e and a corresponding one of the second type of electrical contacts 88.

[0188] In the exemplary conductive layer 80, the first type of electrical connection is located at the first edge of the conductive layer, and the second type of electrical connection is located at the second edge of the conductive layer. This allows for convenient power connections, but of course many other configurations are possible, some of which will be discussed further below.

[0189] Figure 9 shows a conductive layer, collectively referred to as reference numeral 90, according to an exemplary embodiment. The conductive layer 90 is an exemplary implementation of the heating element 24 of the aerosol generator 20 or 30 described above.

[0190] The conductive layer 90 comprises a heating element 92, a first type first electrical connection 94, a first type second electrical connection 95, a second type first electrical connection 96, and a second type second electrical connection 97. In some exemplary embodiments, the first type electrical connection provides a positive electrical connection, and the second type electrical connection provides a negative electrical connection.

[0191] The heating element 92 has a higher electrical resistance than the electrical connections 94-97. This can be caused, at least partially, by the heating element 92 having perforations (not shown in Figure 9).

[0192] During use, current can flow from electrical connection 94 to electrical connection 96 through the conductive layer 92. Similarly, current can flow from electrical connection 95 to electrical connection 97 through the conductive layer 92. The higher resistivity of the heating element 92 (compared to the electrical connections) tends to limit the flow of current between electrical connection 94 and electrical connection 97, and between electrical connection 95 and electrical connection 96. As a result, the conductive layer 90 can be separated into different sections, and these sections can be heated separately (to specific temperatures).

[0193] Figure 10 is a flowchart illustrating an exemplary embodiment of the algorithm, which is collectively referred to as reference number 100.

[0194] Algorithm 100 starts with operation 102, in which a conductive layer is formed on one or more heating elements (e.g., multiple heating elements), and each heating element extends from a first type of electrical connection to a second type of electrical connection.

[0195] In other words, each heating element is at least a portion of the respective conductive path between the respective electrical connections of the first type and the electrical connections of the second type. Such a conductive layer may be considered a blank. An aerosol generator may be formed using this blank.

[0196] The formation of the above or each heating element may be performed before or after attaching the conductive layer to the support, if a support is present. The conductive layer may be attached to the support, or attached to or formed on the support in a different configuration.

[0197] During use, the above-mentioned heating elements may be used to provide a conductive path for generating an aerosol by resistance heating a portion of the aerosolizable material. The conductive layer may be perforated, and a perforation process may be provided as an alternative (discussed further below).

[0198] In operation 104, for example, an aerosolizable layer containing an aerosolizable material is added by bringing the formed conductive layer into contact with the aerosolizable layer.

[0199] In other words, in operation 104, at least one of the formed resistance heating layer and aerosol generating layer is brought into contact with other components, and the aerosol generating layer incorporates an aerosol generating material. In addition, or otherwise, the aerosol generating layer is formed on the resistance heating layer.

[0200] In an optional operation 106, the combination of the heating element and the aerosolizable layer may be brought into contact with the support.

[0201] Therefore, algorithm 100 may be used to generate the aerosol generator 20 or 30 described above (for example, incorporating one of the conductive layers 40, 50, 70, 80, or 90 described above).

[0202] Figure 11 is a flowchart showing the algorithm, collectively referred to as reference no. 110, for forming an aerosol generator according to an exemplary embodiment. In algorithm 110, a conductive layer is perforated, and then a heating element is brought into contact with the aerosolizable layer.

[0203] Algorithm 110 begins with operation 112, in which a perforated conductive layer is obtained. Operation 112 may be implemented by procuring a pre-perforated conductive material, or by perforating the conductive material as the first step (i.e., including the perforation operation).

[0204] In operation 114, for example, the formed (and perforated) conductive layer is brought into contact with the aerosolizable layer, thereby combining the perforated conductive layer with the aerosolizable layer, which incorporates the aerosolizable material (e.g., a gel foam) as discussed above.

[0205] In an optional operation 116, the combination of perforated heating elements(s) and an aerosolizable layer may be brought into contact with the support.

[0206] Figure 12 is a flowchart illustrating the algorithm as a whole, as shown by reference no. 120, according to an exemplary embodiment.

[0207] Algorithm 120 starts with operation 122, in which the conductive layer is brought into contact with the aerosolizable layer, for example, by bringing the formed conductive layer into contact with the aerosolizable layer, and the aerosolizable layer incorporates the aerosolizable material as discussed above.

[0208] In operation 124, a hole is formed in the conductive layer of the heating element. Operation 124 may also include forming a hole in the aerosolizable layer.

[0209] In an optional operation 126, the combination of the heating element and the aerosolizable layer may be brought into contact with the support.

[0210] Figure 13 is a flowchart illustrating the algorithm, as a whole, as shown by reference no. 130, according to an exemplary embodiment.

[0211] Algorithm 130 begins with operation 132, in which the conductive layer is brought into contact with the aerosolizable layer, for example, by which the formed conductive layer is combined with the aerosolizable layer, and the aerosolizable layer incorporates the aerosolizable material as discussed above. Therefore, operation 132 is the same as operation 122 described above.

[0212] In operation 134, the combination of the heating element and the aerosolizable layer is brought into contact with the support.

[0213] In operation 136, a perforation is formed in the conductive layer of the heating element. Operation 124 may also include forming a perforation in the aerosolizable material and / or support.

[0214] In the examples of algorithms 100-130 described above, in which perforations are provided in both the conductive layer and the aerosolizable layer, the perforations in the two layers may be similar. However, this is not necessarily required in all exemplary embodiments. As discussed above, perforations may be provided in the conductive layer to adjust the electrical resistance of the conductive layer. In contrast, perforations may be provided in the aerosolizable layer to allow gas to escape from the layer (acting as vents). Perforations in the aerosolizable layer can help reduce layer delamination in the aerosol generator in some exemplary embodiments. It is not necessary in all exemplary embodiments that the perforations in the two layers are the same. For example, the number and pattern of perforations may differ. Thus, for example, in algorithms 120 and 130, in operation 122 or 132, the perforated conductive layer may be formed together with the uncooked aerosolizable layer, and in operation 124 or 136, further perforations may be provided in both layers. Similarly, algorithm 110 may yield layers perforated in a different way (for example, operation 112).

[0215] In addition to allowing the electrical resistance of the conductive layer to be modified, perforating the aerosolizer comprising the aerosolizable layer and support allows for the formation of a physical bond between the aerosolizable material (e.g., a gel) and the support (if provided) through the perforations in the conductive layer. This facilitates the physical connection of the layers and reduces the risk of delamination of the layers in the aerosolizer. In practice, in some exemplary embodiments, perforation of the aerosolizable layer may be omitted as a result of the reduced risk of delamination.

[0216] Figure 14 shows an aerosol generator, indicated collectively by reference numeral 140, formed according to an exemplary embodiment. The aerosol generator 140 comprises a conductive layer 142 and an aerosolizable layer 144 incorporating an aerosolizable material. The aerosolizable material may be formed on layer 144, for example, by depositing the aerosolizable material, such as by spraying, coating, dispensing, or some other method.

[0217] In an exemplary implementation of operation 102 of algorithm 100 described above, the conductive layer 142 is formed on one or more heating elements. The conductive layer 142 may be, for example, one of the conductive layers 40, 50, 60, 70, 80, or 90 described above.

[0218] In exemplary implementations of operations 104, 114, 122, or 132 of the algorithm described above, the conductive layer 142 and the aerosolizable layer 144 are brought into contact with each other (indicated by arrow 146). The conductive layer 142 may contain perforations, which may be formed in the layer 142 before or after the layer 142 is brought into contact with the support 144 (as discussed above). The aerosolizable layer 144 may or may not have perforations, as discussed above.

[0219] Figure 15 shows the conductive layer 150 formed according to an exemplary embodiment. The conductive layer 150 is cut using a laser cutter 152. The cuts in the conductive layer 150 can be used to form the paths of the heating elements described herein. As discussed above, the conductive layer 150 may include perforations (not shown).

[0220] The use of the laser cutter 152 (or any other cutting process) is not the only way to produce the conductive layer described herein. Several exemplary methods are described below.

[0221] Figure 16 is a flowchart illustrating an exemplary embodiment of the algorithm, as a whole, referred to by reference no. 160.

[0222] Algorithm 160 begins with operation 162, in which a conductive layer is prepared. In operation 164, one or more heating elements are formed on the conductive layer by chemical etching. Operations 162 and 164 are exemplary implementations of operation 102 of algorithm 100 described above. Operation 104 described above is then implemented by bringing the conductive layer into contact with the aerosolizable layer.

[0223] The flowchart in Figure 16 may also be referenced as illustrating part of a method or algorithm for forming aerosol generators 20, 30, and 70. In embodiments, the method or algorithm 160 begins with operation 162, in which a resistance heating layer is prepared. In operation 164, one or more resistance heating elements are formed on the resistance heating layer by chemical etching of the resistance heating layer. Operations 162 and 164 are exemplary implementations of operation 62 of the method 60 described above. Operation 104 described above is then implemented by placing the aerosol generating material on the resistance heating layer.

[0224] Figure 17 is a flowchart illustrating the algorithm, as a whole, as shown by reference no. 170, according to an exemplary embodiment.

[0225] Algorithm 170 begins with operation 172, in which a heating element is formed by printing a conductive layer at least partially. Thus, operation 172 is an exemplary implementation of operation 102 of algorithm 100 described above. Operation 104 described above is then implemented by bringing the conductive layer into contact with the aerosolizable layer.

[0226] The flowchart in Figure 17 may also be referenced as showing a method for forming aerosol generators 20, 30, and 70, or a part of the algorithm as a whole indicated by reference no. 170. The method or algorithm 170 begins with operation 172, in which one or more heating elements are formed by printing a resistance heating layer, at least partially. Thus, operation 172 is an exemplary implementation of operation 162 of algorithm 160 described above. Operation 104 described above is then implemented by placing the aerosol generating material on the resistance heating layer.

[0227] The cutting, etching, and printing methods described above are provided as examples, and alternative methods are also possible. For example, the so-called "hot foiling" technique can be used, in which a heating element is made from a conductive layer and then assembled / bonded to the substrate. Further techniques can also be used, such as die-cutting or punching (e.g., perforation) of the conductive layer. In addition, two or more techniques can be combined (for example, conductivity can be added to the connection trace by adding a more conductive material such as additional foil or printing material). Many further techniques or combinations of techniques that can be used in implementing the principles described herein will be recognized by those skilled in the art.

[0228] Figure 18 is a flowchart illustrating the algorithm, as a whole, as shown by reference no. 180, according to an exemplary embodiment. Algorithm 180 may be implemented, for example, using one of the aerosol generators described herein.

[0229] Algorithm 180 is initiated when a command to initiate heating is received in the case of operation 182. In response to the command to initiate heating, a determination is made as to whether a heating element is available (operation 184). As discussed above, multiple heating elements may be provided by the conductive layers described herein. Operation 184 may also involve a determination as to which of the heating elements has been used (and whether the corresponding available aerosolizable material has been used up).

[0230] If a heating element is available, the algorithm proceeds to operation 186, in which the available heating element is used. As discussed above, the heating elements may be individually controllable, for example, by supplying power to each individual heating element. After operation 186 is completed, the algorithm terminates with operation 188.

[0231] If operation 184 determines that a heating element is unavailable (for example, because all heating elements have been used), the algorithm terminates in operation 188. This may mean that the consumables used to implement algorithm 180 need to be replaced.

[0232] Figure 19 shows a conductive layer, collectively referred to as reference no. 190, according to an exemplary embodiment. The conductive layer 190 may be formed using a laser cutter (similar to the laser cutter 152 described above) or some similar device, but other methods may also be used (such as chemical etching or printing, as discussed above). As discussed above, the conductive layer 190 may include perforations.

[0233] In other words, the resistance heating layer 190 may be formed using the laser cutter 152 described above, or some similar device or other method. Each resistance heating element extends from one of the first type of electrical contacts, for example, a positive electrical contact, to a second type of electrical contact, for example, a negative electrical contact.

[0234] The conductive layer 190 comprises multiple heating elements, each heating element being a linear heating element with a conduction path extending in the longitudinal direction of the support. Each heating element extends from a first type of electrical connection (e.g., a positive electrical connection) to a second type of electrical connection (e.g., a negative electrical connection).

[0235] In the exemplary layer 190, both types of electrical connections are provided at the same end of the layer and adjacent to each other. Thus, the exemplary path of layer 190 extends from one end of the layer to the other and back. Note that there is no common second connection as in some other exemplary embodiments, but each heating element has separate first and second electrical connections.

[0236] Figure 20 shows a conductive layer, collectively referred to as reference numeral 200, according to an exemplary embodiment. The conductive layer 200 may be formed using a laser cutter (similar to the laser cutter 152 described above) or some similar device, but other methods may also be used (such as chemical etching or printing, as discussed above). As discussed above, the conductive layer 200 may include perforations.

[0237] The conductive layer 200 comprises a plurality of heating elements, each heating element being a linear heating element with a conduction path extending in the longitudinal direction of the support. Each heating element extends from a first type of electrical connection (e.g., a positive electrical connection) to a second type of electrical connection (e.g., a negative electrical connection). In the exemplary layer 200, these types of electrical connections are provided at both ends of the layer, and a common second (negative) connection is provided. Although linear paths (not winding paths) are provided, electrical resistance is provided by providing sawtooth-shaped paths. Note that the paths in any other embodiments described herein may also be sawtooth-shaped.

[0238] Figure 21 shows a portion of an aerosol generator 210 according to an exemplary embodiment. As discussed above, the aerosol generator 210 may include a conductive layer having a first type of multiple electrical connections (e.g., providing a positive electrical connection to each of the multiple heating elements) and a second type of single electrical connection (e.g., providing a common negative electrical connection to the multiple heating elements).

[0239] In other words, article 300 has an article electrical contact configuration. This electrical contact configuration is formed by an aerosol generator 210 in an embodiment. This electrical contact configuration includes heater electrical contacts 212, 214. The heater electrical contacts may also be called heater or article contacts 212, 214. The aerosol supply device includes an electrical connector 220, as shown in Figure 22. This electrical connector includes connector electrical contacts. The connector electrical contacts may also be called connector or device contacts. The article electrical contact configuration is configured to communicate electrically with the device electrical connector 220.

[0240] The first and second types of electrical contacts 62, 63, i.e., heater contacts, together form at least a portion of the article electrical contact configuration of the aerosol generators 20, 30, and 70.

[0241] The resistive heating element 60 is located inside the resistive heating layer. The inside defines the first side of the aerosol generator 210. The heater contacts 62 and 63 are located on the second side of the resistive heating layer. The second side defines the outside of the aerosol generator 210. The heater contacts are exposed and therefore can contact the device electrical connector. The heater contacts are located on the opposite side of the resistive heating element from the resistive heating layer. Other configurations are also possible.

[0242] The support layer 32 is located between the inner portion and the outer portion of the resistance heating layer.

[0243] The configuration of article 300 may vary. Article 300 comprises a body 302. The body 302 may be hollow. The body 302 may define a flow path through article 300. The flow path extends between an air inlet and an aerosol outlet. The flow path is defined by an internal space within the article through which air and / or aerosol can flow. The flow path is defined within the body 302. The above or each aerosol generator 210 connects the flow path. The aerosol generating material is exposed in the flow path. The aerosol generating material is exposed in the internal space. In embodiments, the internal space comprises two or more chambers.

[0244] Figure 21 shows the distal end of article 300. As shown, the body 302 comprises a plurality of body layers. The body layers are arranged in a stack of body layers 304. The body layers form a laminate. In embodiments, the body layers are cardboard layers. Other suitable materials may be used. The body layers 304 are configured to define the features of article 300. In embodiments, at least one body layer has a gap that defines an air inlet. The gap defines an opening 306.

[0245] The air inlet includes an opening 306. The opening is formed within the main body 302. In the embodiment, the opening 306 is formed in another component of the article 300, for example, the aerosol generator 210 or another wall feature. The aerosol outlet includes an outlet opening. The outlet opening is formed within the main body 302. In the embodiment, the outlet opening is formed in another component of the article 300, for example, the aerosol generator 210 or another wall feature.

[0246] In an embodiment, article 300 may comprise two aerosol generators 210 that form an aerosol generator configuration. The number of aerosol generators 210 may vary. Each aerosol generator 210 comprises an aerosol generating material. The aerosol generating material is exposed in the flow path. In an embodiment, article 300 comprises a single aerosol generator 210.

[0247] The aerosol generator 210 is equipped with multiple external connectors, the configuration of which depends on the configuration of the first and second types of electrical connections of the aerosol generator. For example, the aerosol generator shown in Figure 21 is equipped with multiple external connectors indicated by reference numeral 212 (each connected to one of the first type of electrical connections) and a further external connector 214 (connected to the second type of electrical connection). The aerosol generator 210 may have further external connectors corresponding to connectors 212 and 214 located on the underside of the device (not visible in Figure 21).

[0248] Figure 22 shows a connector 220 used in some exemplary embodiments. This connector has separate pins for connecting to electrical contacts such as the connectors 212 and 214 described above.

[0249] Figure 23 is a block diagram of an aerosol generating device, shown as a whole by reference numeral 230, according to an exemplary embodiment. The system comprises the aerosol generator 230 described above, a first connector 220a and a second connector 220b (similar to the connector 220 described above), and a control section 232.

[0250] The control section 232 is similar to the control section 2 of the aerosol generating device 10 described above with reference to Figure 1. The aerosol generator 210 is similar to the consumable 4 of the aerosol generating device 10. Connectors 220a and 220b enable the control section 232 to provide regulated or controlled voltage and / or current to various first and second types of electrical connections of the aerosol generator 210 when the aerosol generator 210 is inserted into the control section 232 (as shown in Figure 23). The control section 232 may implement, for example, the algorithm 180 described above.

[0251] In some embodiments of the different components of the aerosol generator and article described above, the aerosol-generating material is formed in a configuration other than that of an aerosol-generating layer. In embodiments, the aerosol-generating material is in the form of an aerosol-generating segment. The aerosol-generating segment generally comprises a solid material. Such a solid material may be shredded cigarette. For example, the aerosol-generating material arranged as an aerosol-generating segment may comprise a plurality of individual aerosol-generating material pieces. The aerosol-generating material may also comprise individual cigarette material pieces. In embodiments, the aerosol-generating material comprises a plurality of fragments, beads, or pellets. In embodiments, the aerosol-generating segment is a material plug.

[0252] In some embodiments, the aerosol-generating segment includes a material body. The aerosol-generating material is non-liquid. In such embodiments, the material body constitutes a rod of the aerosol-generating material, for example, a tobacco rod. For example, the material body may include shredded tobacco material. The material body may be formed into a rod. In some embodiments, the material body includes shredded rag tobacco formed into a rod. The aerosol-generating material may include tobacco material. The aerosol-generating material may include extruded tobacco. The aerosol-generating material may include recycled tobacco.

[0253] The aerosol-generating material, formed as a solid material, may contain nicotine. The aerosol-generating material may contain tobacco, consist of tobacco, or consist essentially of tobacco. In the embodiment, the aerosol-generating material does not contain tobacco.

[0254] In any of the embodiments described above, heating the article provides a relatively constant release of volatile compounds into an inhalable medium. In one embodiment described above, the aerosol-generating segment is a material plug. The article may comprise a mouthpiece end section. A tubular element may be located between the aerosol-generating material and the mouthpiece end section. The article may comprise a ventilation area within the mouthpiece end section. The mouthpiece end section may define a mouthpiece configured to be positioned between the user's lips.

[0255] In any embodiment of the articles described above, the above or each resistance heating element is configured to heat substantially the entire aerosol-generating material. The aerosol-generating segment is, in embodiments, at least substantially cylindrical. In embodiments, the aerosol-generating segment is at least partially wrapped by a resistance heating layer. In embodiments, the resistance heating element extends into the aerosol-generating segment. The resistance heating element may extend around the aerosol-generating segment. In embodiments, the resistance heating element surrounds the aerosol-generating segment. In some configurations, at least a portion of the flow path through the article passes through the aerosol-generating segment. The aerosol-generating segment may define a portion of the air path. In embodiments, a first type of electrical contact and a second type of electrical contact are exposed from the aerosol-generating segment.

[0256] The aerosol-generating material may include the tobacco material described herein, and the tobacco material contains tobacco components. In the tobacco material described herein, the tobacco components may include recycled tobacco. The tobacco components may also include loose tobacco, extruded tobacco, and / or band-cast tobacco. The tobacco material may be provided in the form of shredded rag tobacco. Shredded rag tobacco can be formed from a mixture of the forms of tobacco material, for example, a mixture of one or more of recycled tobacco, loose tobacco, extruded tobacco, and band-cast tobacco. In embodiments, the tobacco material includes recycled tobacco, or a mixture of recycled tobacco and loose tobacco. In the tobacco material described herein, the tobacco material may contain filler components. The filler components are generally non-tobacco components, i.e., components that do not contain tobacco-derived raw materials. The filler components may be non-tobacco fibers such as wood fibers or pulp or wheat fibers. The filler components may also be inorganic materials such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, and magnesium carbonate. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. The filler component may be present in an amount of 0 to 20% by weight of the tobacco material, or in an amount of 1 to 10% by weight of the composition. In some embodiments, the filler component is absent. In the tobacco materials described herein, the tobacco material contains an aerosol-forming material. In this context, “aerosol-forming material” is an active substance that promotes aerosol formation. The aerosol-forming material can promote aerosol formation by promoting initial vaporization and / or condensation from gas to inhalable solid and / or liquid aerosols. In some embodiments, the aerosol-forming material can improve the delivery of flavor from the aerosol-forming material. Generally, any suitable aerosol-forming material or active substance, including those described herein, may be included in the aerosol-forming material of the present invention.

[0257] Recycled tobacco refers to tobacco material formed by a process in which tobacco raw materials are extracted with a solvent to yield an extract of residue containing soluble substances and fibrous materials, and then the extract (usually concentrated and optionally further processed) is recombined with fibrous materials from the residue (usually purified and optionally with some non-tobacco fibers added) through deposition of the extract onto the fibrous material. This recombination process is similar to the papermaking process.

[0258] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations to the scope of the invention as defined by the claims, or to equivalents of the claims, and that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may preferably include, consist of, or essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. Aerosol generator for articles for aerosol supply devices, Aerosol generating materials and A resistance heating layer comprising a resistance heating element configured to generate an aerosol by heating at least a portion of the aerosol generating material, It is equipped with, The resistive heating element is at least a portion of the conductive path between the first type of electrical contact and the second type of electrical contact. An aerosol generator in which the resistance heating layer includes multiple surface features.

2. The aerosol generator according to claim 1, wherein the plurality of surface features include a plurality of perforations.

3. The aerosol generator according to claim 1 or 2, wherein the plurality of surface features include at least one of a plurality of recesses and a plurality of protrusions.

4. The aerosol generator according to any one of claims 1 to 3, wherein at least some of the surface features are formed along the conductive path.

5. The aerosol generator according to claim 4, wherein the plurality of surface features are configured to at least partially determine the electrical resistance along the conductive path.

6. An aerosol generator according to any one of claims 1 to 5, comprising the array of surface features.

7. An aerosol generator according to any one of claims 1 to 7, comprising an aerosol generating layer containing the aerosol generating material.

8. The aerosol generator according to claim 7, wherein the aerosol generating layer includes a plurality of aerosol generating layer perforations.

9. The aerosol generator according to claim 8, wherein the plurality of surface features of the resistance heating layer are aligned with the plurality of aerosol generation layer perforations.

10. The aerosol generator according to any one of claims 7 to 9, wherein the aerosol generating layer does not contain perforations.

11. The aerosol generator according to any one of claims 1 to 10, comprising a support configured to support the resistance heating layer.

12. The aerosol generator according to claim 11, wherein the support does not contain perforations.

13. The aerosol generator according to claim 11, wherein the support includes a plurality of support perforations.

14. The aerosol generator according to claim 13, wherein the plurality of surface features of the resistance heating layer are aligned with the plurality of support holes.

15. The aerosol generator according to any one of claims 1 to 16, wherein at least one resistive heating element has an electrical resistance different from that of another of the resistive heating elements, and at least one of a plurality of surface features different from that of another of the resistive heating elements.

16. an aerosolizable layer incorporating an aerosolizable material, The conductive layer in contact with the aerosolizable layer and an aerosol generator comprising, wherein the conductive layer comprises a plurality of perforations, the conductive layer comprises one or more heating elements, the or each heating element provides a conductive path for resistance heating of a portion of the aerosolizable material to generate an aerosol, and the or each heating element extends from a first type of electrical connection to a second type of electrical connection.

17. An article comprising an aerosol generator according to any one of claims 1 to 16.

18. An aerosol generator according to any one of claims 1 to 16 or an aerosol supply device configured to receive an article according to claim 17.

19. an aerosol generator according to any one of claims 1 to 16 or an article according to claim 17, an aerosol generator or an aerosol supply device configured to receive the article and An aerosol supply system equipped with the following features.

20. A blank for forming an aerosol generator for an aerosol supply device, A resistance heating layer is formed, wherein the heating element provides a conductive path for resistance heating. The first type of electrical contact, The second type of electrical contact and It is equipped with, The heating element extends between the first type of electrical contact and the second type of electrical contact, A blank in which the resistance heating layer includes a plurality of surface features.

21. The steps include forming a resistance heating layer equipped with a resistance heating element, A step of providing an aerosol generating material to the resistance heating layer, wherein the resistance heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol, The step of providing that the resistive heating element is at least a portion of the conductive path between a first type of electrical contact and a second type of electrical contact, The steps include forming multiple surface features on the resistance heating layer and Methods that include...

22. A step of forming a conductive layer on one or more heating elements, wherein the heating element or each heating element provides a conductive path for resistively heating a portion of an aerosolizable material to generate an aerosol; A step of bringing the formed conductive layer into contact with an aerosolizable layer, wherein the aerosolizable layer incorporates the aerosolizable material and is in contact with the aerosolizable material. Includes, The above or each heating element extends from a first type of electrical connection to a second type of electrical connection, A method wherein the conductive layer includes a plurality of perforations.

Images