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 (340) having a resistance heating element (342) configured to heat at least a portion of the aerosol generating material to generate an aerosol, the aerosol generating material on the resistance heating layer (340) and a first type of electrical contact (360), a second type of electrical contact (365), and folds (370a, 378a) in the resistance heating layer for defining the electrical contact area of ​​at least one of the first type of electrical contact and the second type of electrical contact. The resistance 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.

Description

Technical Field

[0002] ,

[0004] , , , , , , , ,

[0003]

[0001] The present invention relates to an aerosol generator for an article for an aerosol supply device. The present invention also relates to an aerosol supply system, a method of forming an aerosol generator for an article for an aerosol supply device, and a blank for forming an aerosol generator for an article for an aerosol supply device.

Background Art

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

[0003] Aerosol supply systems covering the above-described devices or products are known. A common system uses a heater to generate an aerosol from a suitable medium, and then the aerosol is inhaled by the user. Often, the medium used needs to be replaced or changed to provide different aerosols for inhalation. It is known to use a resistive heating system as a heater for generating an aerosol from a suitable medium.

Summary of the Invention

[0005] In any of the embodiments described above, 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.

[0006] In any of the embodiments described above, the article is cylindrical.

[0007] In any of the embodiments described above, the resistance heating layer has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and width, wherein the length is greater than or equal to the width, and the width is greater than the depth.

[0008] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact may extend from the fold.

[0009] In any of the embodiments described above, the first type of electrical contact and the second type of electrical contact may extend from the fold.

[0010] In any of the embodiments described above, the fold may define an electrical contact area of ​​at least one of a first type of electrical contact and a second type of electrical contact extending from the fold.

[0011] In any of the above embodiments, the aerosol generator may be elongated and may have a defined longitudinal axis.

[0012] In any of the embodiments described above, the fold may extend along an axis perpendicular to the longitudinal axis.

[0013] In any of the embodiments described above, the fold may define the longitudinal end of the aerosol generator.

[0014] In any of the above embodiments, the aerosol generator may be elongated and may have a defined longitudinal axis.

[0015] In any of the embodiments described above, the fold may extend along an axis parallel to the longitudinal axis.

[0016] In any of the embodiments described above, the fold may be a first fold that defines a first type of electrical contact.

[0017] In any of the above embodiments, the aerosol generator may have a second fold.

[0018] In any of the embodiments described above, the second fold may define a second type of electrical contact.

[0019] In any of the embodiments described above, the first and second folds may be spaced apart from each other.

[0020] In any of the embodiments described above, the first and second folds may extend parallel to each other.

[0021] In any of the embodiments described above, the first and second folds may extend in the longitudinal direction.

[0022] In any of the embodiments described above, the fold can define the terminal edge of the aerosol generator.

[0023] In any of the above embodiments, the terminal edge may extend perpendicular to the longitudinal direction of the aerosol generator.

[0024] In any of the above embodiments, the resistive heating layer may include a heating element panel having a resistive heating element and a contact panel having at least one of a first type of electrical contact and a second type of electrical contact.

[0025] In any of the above embodiments, the fold may be between the heating element panel and the contact panel.

[0026] In any of the above embodiments, the fold may be a first fold.

[0027] In any of the above embodiments, the aerosol generator may include a second fold.

[0028] In any of the above embodiments, the first fold may extend perpendicular to the second fold to define an end fold.

[0029] In any of the above embodiments, the first fold may extend perpendicular to the longitudinal axis of the aerosol generator.

[0030] In any of the above embodiments, the first fold may define a flap.

[0031] In any of the above embodiments, the flap may be between the heating element panel and the contact panel.

[0032] In any of the above embodiments, the first fold may be an end fold.

[0033] In any of the above embodiments, the second fold may extend longitudinally.

[0034] In any of the above embodiments, the first fold may define a terminal edge.

[0035] In any of the above embodiments, the flap may be sandwiched between the heating element panel and the contact panel.

[0036] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact may be defined by the first fold.

[0037] In any of the embodiments described above, the folds can define a first type of electrical contact and a second type of electrical contact, respectively.

[0038] In any of the above embodiments, the aerosol generator comprises an aerosol generating layer containing an aerosol generating material. In any of the above embodiments, the aerosol generating layer is located on a resistance heating layer.

[0039] In any of the above embodiments, the aerosol generator includes a support configured to support a resistance heating layer.

[0040] In any of the above embodiments, the support includes a support layer.

[0041] In any of the above embodiments, the aerosol generator may include a support layer.

[0042] In any of the above embodiments, the resistance heating layer may be located on the support layer.

[0043] In any of the above embodiments, the support layer may be electrically insulating.

[0044] In any of the embodiments described above, the support includes at least one of paper and card.

[0045] In any of the embodiments described above, the resistance heating layer and the support layer are each folded at the fold.

[0046] In any of the above embodiments, the aerosol generating material is in direct contact with the resistance heating layer.

[0047] In any of the above embodiments, the aerosol generating material is indirectly in contact with the resistance heating layer.

[0048] In any of the embodiments described above, the resistance heating layer and the support layer define the substrate.

[0049] In any of the above embodiments, the aerosol generator comprises a laminate including a resistance heating layer and a support layer.

[0050] In any of the above embodiments, the laminate includes an aerosol-generating layer.

[0051] In any of the above embodiments, the support layer includes a card layer.

[0052] In any of the embodiments described above, the first type of electrical contact is configured to be electrically connected to the device electrical connector, and the second type of electrical contact is configured to be electrically connected to the device electrical connector.

[0053] In any of the embodiments described above, the support defines the exposed contact area of ​​the first type of electrical contact.

[0054] In any of the embodiments described above, the exposed contact area is a first exposed contact area, and the support defines a second exposed contact area of ​​a second type of electrical contact.

[0055] In any of the above embodiments, the aerosol generation layer is a continuous aerosol generation layer.

[0056] In any of the above embodiments, the aerosol generation layer is a discontinuous aerosol generation layer.

[0057] In any of the above embodiments, the aerosol generation layer comprises a plurality of individual aerosol generation portions.

[0058] In any of the above embodiments, the resistance heating element may be one of a plurality of resistance heating elements.

[0059] In any of the embodiments described above, one of the individual aerosol generating sections is associated with a corresponding one of a plurality of resistance heating elements.

[0060] In any of the above embodiments, the aerosol-generating layer comprises at least one of dots, strips, and patches.

[0061] In any of the embodiments described above, the resistance heating element is a first heating element, the resistance heating layer forms a second resistance heating element, and each resistance heating element provides a conductive path for resistance heating of a portion of the aerosol generating material to generate an aerosol in each portion of the aerosol generating layer.

[0062] In any of the above embodiments, 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.

[0063] In any of the embodiments described above, the aerosol generator comprises a plurality of first-type electrical contacts, and each of the heating elements comprises a separate first-type electrical contact.

[0064] In any of the embodiments described above, the aerosol generator comprises a plurality of second types of electrical contacts, and each of the resistance heating elements comprises a separate second type of electrical contact.

[0065] In any of the above embodiments, the aerosol generator comprises a single second type of electrical contact.

[0066] In any of the embodiments described above, a single second type of electrical contact is shared among each of the resistive heating elements. In any of the embodiments described above, each of the first type of electrical contact and each of the second type of electrical contact is configured to allow current to be supplied individually to each of the resistive heating elements.

[0067] In any of the above embodiments, the aerosol generating layer includes a film or gel layer containing an aerosol generating material.

[0068] In any of the above embodiments, the resistance heating element is formed by at least one of the following steps: cutting the resistance heating layer, chemically etching the resistance heating layer, forming or pressing the resistance heating layer into a substrate, and printing the resistance heating layer.

[0069] In any of the above embodiments, the resistance heating layer is in the form of a foil.

[0070] In any of the above embodiments, a gap is provided in the resistance heating layer that defines at least a portion of the resistance heating element. In any of the above embodiments, the gap defines an electrical insulating barrier. In any of the above embodiments, the gap defines an insulating barrier. In any of the above embodiments, there is no gap in the support layer. In any of the above embodiments, the gap extends through both the support layer and the resistance heating layer. In the embodiment, the gap is a gap filled with, for example, an insulating material.

[0071] In any of the above embodiments, the aerosol generator is formed at least partially by cutting the resistance heating layer and the support together. In any of the above embodiments, the aerosol generator is formed at least partially using die cutting.

[0072] According to one embodiment, an article is provided that comprises an aerosol generator according to any of the embodiments described above.

[0073] In any of the above embodiments, the article may be a consumable of the aerosol generation system.

[0074] According to one embodiment, an aerosol supply device is provided that is configured to receive an aerosol generator as described above or an article of any of the embodiments described above.

[0075] According to one embodiment, an aerosol generation system is provided that comprises an article of any of the embodiments described above.

[0076] In any of the embodiments described above, the aerosol supply device may be configured to receive an article.

[0077] According to one embodiment, an aerosol generator or an aerosol supply device comprising an article according to any of the above is provided.

[0078] According to one embodiment, a blank for forming an aerosol generator is provided, comprising: a resistance heating layer comprising a resistance heating element configured to heat at least a portion of an aerosol generating material on the resistance heating layer to generate an aerosol; a first type of electrical contact; a second type of electrical contact; and a fold line in the resistance heating layer for defining the electrical contact region of at least one of the first type of electrical contact and the second type of electrical contact. The resistance 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.

[0079] In any of the above embodiments, the blank may comprise an aerosol-generating layer containing an aerosol-generating material.

[0080] In any of the above embodiments, the aerosol generating material may be located on a resistance heating layer.

[0081] According to one embodiment, a method for manufacturing an aerosol generator is provided, comprising the steps of: preparing a resistance heating layer; forming a first type of electrical contact of the aerosol generator; forming a second type of electrical contact of the aerosol generator; forming a resistance heating element on the resistance heating layer, wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact; and folding the resistance heating layer along a fold line to form a crease that defines the electrical contact area of ​​at least one of the first type of electrical contact and the second type of electrical contact.

[0082] In any of the above embodiments, the method may include depositing an aerosol-generating material, which includes the aerosol-generating material, onto a resistance heating layer so that a resistance heating element can heat at least a portion of the aerosol-generating material to generate an aerosol. In any of the above embodiments, the aerosol-generating material may be in the form of an aerosol-generating layer.

[0083] In any of the embodiments described above, the first type of electrical contact may be formed on a resistance heating layer.

[0084] In any of the embodiments described above, the second type of electrical contact may be formed on the resistance heating layer.

[0085] According to one embodiment, an aerosol generator for an article for an aerosol supply device is provided, comprising: an aerosol generating material; a resistance heating layer having a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; a first type of electrical contact; and a second type of electrical contact, wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact.

[0086] According to one embodiment, an aerosol supply device is provided that is configured to receive an aerosol generator or article for any of the above-mentioned aerosol supply devices.

[0087] According to one embodiment, an aerosol supply system is provided comprising an aerosol generator or article for any of the above-mentioned aerosol supply devices and any of the above-mentioned aerosol supply devices.

[0088] Next, various embodiments will be described as mere examples, with reference to the attached schematic diagram. [Brief explanation of the drawing]

[0089] [Figure 1] This is a schematic perspective view of an aerosol supply system. [Figure 2] Figure 1 is a schematic perspective view of an article containing aerosol-generating material for the aerosol supply system. [Figure 3] Figure 2 is a schematic perspective view of the first side of the aerosol generator of the article. [Figure 4] Figure 3 is a schematic perspective view of a portion of the second side of the aerosol generator. [Figure 5] Figure 1 is a schematic block diagram of an aerosol supply system, such as the one shown. [Figure 6] Figure 2 is a schematic partially exploded perspective view of the article, showing the aerosol generator reversed from its assembled orientation and separated from the other components. [Figure 7] Figure 3 is a schematic cross-sectional view of another aerosol generator, such as the aerosol generator shown. [Figure 8] Figure 3 is a schematic plan view of the heating element of the aerosol generator. [Figure 9] Figure 3 is a schematic plan view of the resistance heating layer of an aerosol generator having multiple heating elements. [Figure 10] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 11] This is a disassembled perspective view of the formed aerosol generator. [Figure 12] This is a schematic perspective view of the resistance heating layer of the aerosol generator that has been formed. [Figure 13] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 14] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 15] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 16] This is a schematic perspective view of the resistance heating layer of the aerosol generator that has been formed. [Figure 17] This is a schematic plan view of the heating element of the aerosol generator. [Figure 18] This is a schematic plan view of the heating element of the aerosol generator. [Figure 19] Figure 2 is a schematic perspective view of a portion of the aerosol generator of the item shown. [Figure 20] Figure 1 is a schematic perspective view of the device connector of the aerosol supply device in the aerosol supply system. [Figure 21] Figure 1 is a schematic side view of the aerosol generation system. [Figure 22] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 23] This shows a blank for forming the aerosol generator that has been created. [Figure 24A] This shows a blank for forming an aerosol generator. [Figure 24B] This figure shows another blank for forming an aerosol generator. [Figure 25] This shows an aerosol generator formed from a blank. [Figure 26] A schematic perspective view of the aerosol generator is shown. [Figure 27] Figure 26 shows a schematic perspective view of the distal end of the aerosol generator. [Figure 28] This shows part of the process of forming an aerosol generator. [Figure 29]This shows part of the process of forming an aerosol generator. [Figure 30] This shows part of the process of forming an aerosol generator. [Figure 31] This shows part of the process of forming an aerosol generator. [Figure 32] A flowchart illustrating the method for forming an aerosol generator is shown. [Modes for carrying out the invention]

[0090] As used herein, the term “delivery mechanism” is intended to encompass a system for delivering a substance to a user, and includes non-combustible aerosol supply systems that release compounds from aerosolizable materials without burning the aerosolizable materials, such as a hybrid system for generating aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosolizable materials, and articles comprising aerosolizable materials and configured for use in one of these non-combustible aerosol supply systems.

[0091] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or components thereof) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0092] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0093] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0094] In some embodiments, the non-combustion 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.

[0095] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises 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.

[0096] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0097] In some embodiments, the disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-combustible aerosol supply devices. These consumables may be referred to as articles throughout the disclosure.

[0098] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, a power supply.

[0099] In some embodiments, the non-combustion aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a suction port, a filter, and / or an aerosol modifier.

[0100] In some embodiments, consumables for use with a non-combustible 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, packaging material, a filter, a suction nozzle, and / or an aerosol modifier.

[0101] As used herein, “aerosol-generating material” (sometimes referred to herein as “aerosolizable material”) is a material that can generate an aerosol when heated, irradiated, or electrically charged in any other manner. The aerosol-generating material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0102] In some embodiments, the delivered substance includes an active substance (sometimes referred to herein as an active compound).

[0103] The aerosol-generating material may include one or more active substances and / or flavoring agents, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0104] The aerosol-generating material may include a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers may also be present. Optionally, a solvent such as water may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0105] 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 a binder such as a gelling agent and an aerosol-forming agent. Optionally, a delivered substance and / or fillers may also be present. The aerosol-generating film may not contain substantially any plant material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco-free.

[0106] 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.

[0107] The aerosol-generating film may be continuous. For example, the film may consist of a continuous sheet of material, or it may be a continuous sheet of material.

[0108] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual parts or regions of an aerosol-generating material, such as dots, stripes, or lines, which can be supported on a support. In such embodiments, the support may be planar or non-planar.

[0109] The aerosol-generating film may be formed by combining a binder 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 a portion of the solvent to form the aerosol-generating film.

[0110] The slurry may be heated to remove at least about 60% by weight, 70% by weight, 80% by weight, 85% by weight, or 90% by weight of the solvent.

[0111] 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 capable of holding some fluid, such as a liquid, within it. 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.

[0112] The aerosol-forming agent material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent 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.

[0113] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0114] The material may be present on or within a support to form a substrate. The support may be, for example, paper, cardboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may comprise these materials.

[0115] An aerosol supply device can receive an article containing an aerosol-generating material for heating. In this context, "article" refers to a component that contains or is contained with the aerosol-generating material at the time of use, which is heated to volatilize the aerosol-generating material, and optionally, other components at the time of use. The user may insert the article into or onto the aerosol supply device before the article is heated to generate an aerosol, after which the user inhales the aerosol.

[0116] 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 supply thermal energy to the aerosol-generating material in order to release one or more volatile substances from the aerosol-generating material to form an aerosol.

[0117] Consumables are articles containing or consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. Consumables may also 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, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may comprise, for example, a material that can be heated by electrical conductivity.

[0118] A non-combustible aerosol supply system may comprise a modular assembly that includes both a reusable aerosol supply device and replaceable aerosol products. In some implementations, the non-combustible aerosol supply device may comprise a power source and a controller (or control circuit). The power source may comprise a power source such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol supply device may also comprise an aerosol generating component. However, in other implementations, the aerosol product may comprise the aerosol generating component partially or entirely.

[0119] Figure 1 shows a schematic diagram of the aerosol supply system 100. The aerosol supply system 100 comprises an aerosol supply device 200 and an article 300 containing an aerosol generating material 302 (see Figure 3). In Figure 2, the article 300 is shown detached from the aerosol supply device 200. The aerosol generator 304 of the article 300 is shown in Figure 3 by a perspective view of the first side 306, and a perspective view of a portion of the second side 307 is shown in Figure 4.

[0120] Article 300 includes an aerosol generator 304. The aerosol generator 304 is configured to generate an aerosol from an aerosol-generating material 302 when the aerosol supply system 100 is in operation, as will be described in detail below.

[0121] The aerosol supply system 100 may be elongated and extend along its longitudinal axis. The aerosol supply system 100 has a proximal end 102 closest to the user (e.g., the user's mouth) when used by the user for inhaling the aerosol generated by the aerosol supply system 100, and a distal end 104 furthest from the user when used.

[0122] The proximal end may also be called the “mouthpiece end.” Thus, the aerosol supply system 100 defines a proximal direction that is directed toward the user during use. Furthermore, the aerosol supply system 100 similarly defines a distal direction that is directed away from the user during use. The terms “proximal” and “distal” applied to the features of system 100 are explained by referring to the relative positioning of such features relative to each other in the proximal-distal direction along the longitudinal axis.

[0123] Article 300 is received by an aerosol supply device 200. The configurations of article 300 and the aerosol supply device 200 may vary. In this embodiment, the aerosol supply device 200 includes a device body 202. The device has a housing 204 that encloses the components of the device 200. As shown in Figure 5, an article receiving portion 206, sometimes called a device chamber, is configured to receive a portion of article 300. The proximal end 308 of the article protrudes from the device 200 when article 300 is received within the device chamber 206. A receptacle 208 defines the chamber 206. The receptacle 208 comprises a receptacle base 210 and a receptacle periphery 212. The configuration of the receptacle 208 may vary depending on the configuration of article 300.

[0124] One or more user-operable control elements 224, such as buttons or switches, may be provided on the aerosol supply device 200 for use in operating the aerosol supply system 100. For example, a user can activate the system 100 by pressing a control element 224.

[0125] The aerosol supply device 200 includes an opening 214 at its proximal end that leads to a device chamber 206. The opening 214 is located at one end through which an article 300 can be inserted. In embodiments, the article 300 can be fully or partially inserted into the device 200. The configuration of the device 200 may vary; for example, the opening may be located on the longitudinal side wall of the device 200 and / or may be closed by another feature of the device 200 during use. In this configuration, the article 300 defines a mouthpiece 310 at its proximal end 308. In other embodiments, the device 200 defines the mouthpiece. The user places their mouth over the mouthpiece during use.

[0126] Device 200 defines a longitudinal axis along which article 300 may extend when inserted into device 200. The opening 214 is aligned on the longitudinal axis. The longitudinal axis may be the axis along which article 300 is inserted into device 200. The longitudinal axis may be considered the receiving axis of device 200. Article 300 may also have a longitudinal axis along which it is inserted into the device, and this axis may be considered the insertion axis.

[0127] The aerosol supply device 200 includes a power source 220. The power source 220 may be a battery, for example, a rechargeable battery. The device 200 also includes a control circuit 222 which functions as a controller, comprising a processor and memory.

[0128] As will be discussed in detail below, the heating system 110 is configured to heat the aerosol-generating material 302 of article 300. Article 300 in the embodiment is a consumable and interchangeable with other articles 300. The heating system 110 comprises an aerosol generator 304. The heating system 110 includes article 300 and other components of the aerosol supply system 100, including components of the aerosol supply device 200, such as a power source 220 and a control circuit 222.

[0129] The aerosol generator 304 forms part of article 300. The aerosol generator 304 includes a heating component 312 configured to generate an aerosol by heating at least one of an aerosol-generating material 302, such as a film and a gel. The aerosol-generating material may be called an aerosolizable material.

[0130] The heating element 312 is a resistance heating element. In the embodiment, the heating element or each heating element is a resistance heating element, as will be described in detail below. In such a configuration, the heating system 110 includes a resistance heating generator which includes components for heating the heating element 312 by a resistance heating process. In this case, a current is applied directly to the resistance heating element, and the resulting current flow within the heating element, which functions as a heating component, heats the heating element by Joule heating. The resistance heating element includes a resistance material configured to generate heat when a suitable current passes through the resistance heating element, and the heating element 312 includes electrical contacts for supplying current to the resistance material. The provision of the resistance heating element 312 enables a compact configuration. Resistance heating provides an efficient configuration.

[0131] In the use of the aerosol supply system 100, air is drawn into the air inlet 314 of the article 300, as indicated by arrow 316. The air inlet 314 is located at the distal end of the article 300. In embodiments, the air inlet 314 may have different configurations, for example, on the side. The airflow to the air inlet 314 of the article 300 may be defined by at least one of the following: an air path through the device 200, an air path outside the device 200, and an air path between the device 200 and the article 300. The aerosol generated by the aerosol generator 304 exits the device at the aerosol outlet 318, as indicated by arrow 319. In embodiments, the aerosol outlet 318 is located in the mouthpiece of the article 300 so that the aerosol is drawn directly from the article 300 to the user's mouth in the device 10.

[0132] In some exemplary embodiments, an aerosol supply system includes two main components: a control section that forms reusable parts and a consumables section that forms replaceable or disposable parts, which may be called replaceable or disposable articles or cartridges. As described herein, the aerosol supply device 200 forms the control section, and the article 300 forms the consumables section. In the use of the aerosol generation system, the control section and the consumables may be releasably connected at an interface. The consumables may be removable and replaceable, for example, when the consumables are used, and the control section may be reused with different consumables.

[0133] The illustrated aerosol supply system 100 is provided merely as an example and is highly schematic. Different 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 a control section, passes through an interface, and exits through consumable parts.

[0134] As schematically shown in Figure 5 and described in detail below, article 300 has article electrical contact configuration 320. In this embodiment, the electrical contact configuration 320 is formed by an aerosol generator 304. The electrical contact configuration 320 includes a heater electrical contact 322. The heater electrical contact 322 may also be known as a heater or article contact. The aerosol supply device 200 includes an electrical connector 230. The electrical connector 230 includes a connector electrical contact 232. The connector electrical contact 232 may also be known as a connector or device contact. The article electrical contact configuration 320 is configured to communicate electrically with the device electrical connector 230.

[0135] The configuration of article 300 may vary. Article 300 comprises a body 324, which is hollow. The body 324 defines a flow path 326 (see Figure 6) through article 300. The flow path 326 extends between an air inlet 314 and an aerosol outlet 318. The flow path 326 is defined by an internal space within the article through which air and / or aerosols can flow. The flow path 326 is defined within the body 324. An aerosol generator or each aerosol generator 304 borders the flow path 326. The aerosol generating material 302 is exposed to the flow path 326. The aerosol generating material 302 is exposed in the internal space. In the embodiment, the internal space comprises two or more chambers.

[0136] The air inlet 314 includes an opening 315. The opening 315 is formed in the body 324. In embodiments, the opening is formed in another component of the article 300, for example, an aerosol generator 304 or another wall feature. The aerosol outlet 318 includes an outlet opening 317. The outlet opening 317 is formed in the body 324. In embodiments, the outlet opening 317 is formed in another component of the article 300, for example, an aerosol generator 304 or another wall feature.

[0137] As shown in Figure 6, article 300 includes two aerosol generators 304 that form an aerosol generator configuration. The number of aerosol generators 304 may vary. Each aerosol generator 304 contains an aerosol generating material 302. The aerosol generating material 302 is exposed to a channel 326. In embodiments, article 300 includes a single aerosol generator 304. One of the aerosol generators 304 is described in detail, and such details are applicable to one or more further aerosol generators 304 in embodiments.

[0138] The aerosol generator or each aerosol generator 304 and the main body 324 are formed in a stacked configuration. In embodiments, other arrangements such as a tubular arrangement of articles are envisioned. In such a tubular arrangement, the aerosol generator 304 defines a tubular configuration. The tubular shape may include a circular cross-section, an elliptical cross-section, and other polygonal shapes.

[0139] In this embodiment, as shown in the figure, article 300 has a flat configuration. That is, in this case, 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.

[0140] Figure 6 is an exploded perspective view of article 300, in which the aerosol generator 304 is shown inverted from its assembled orientation and spaced apart from the other components. Article 300 includes a first aerosol generator 302, a body 324, and a second aerosol generator 304. The body 324 separates the first and second aerosol generators 304. The first and second aerosol generators 304 enclose an internal space defined by the body 324 through which air and / or aerosols can flow. The aerosol-generating materials 302 of the first and second aerosol generators 304 are exposed to the internal space facing each other. When assembled, the first and second aerosol generators 304 sandwich the body 324. In the embodiment of Figure 6, at least the first and second aerosol generators 304 and the body have equal planar areas. In the embodiment, one or more of the first and second aerosol generators 304 and the body 324 have a greater length and / or width. In the embodiment, one of the first and second aerosol generators 304 is replaced by a blank panel. The body 324 includes a body layer. The body may include multiple body layers. The body layers are formed within the laminate and may be arranged to define features of the article 300, such as an air inlet 314 and an aerosol outlet 318.

[0141] The wrap surrounds the article 300 and forms part of the article 300. The wrap may include a sheet. The wrap functions as a fixing sleeve. The aerosol generator or each aerosol generator 304 protrudes from the wrap at its distal end. The exposed electrical contact area 323 of the heater contact 322 is exposed at its distal end. Other configurations are conceivable, for example, at least one exposed electrical contact area 323 may be additionally or alternatively defined on the main surface of the article defined by the aerosol generator 304, along a short longitudinal surface or edge of the article 300.

[0142] The aerosol generator 304 is schematically shown in cross-section in Figure 7. The aerosol generator 304 is an implementation of the aerosol generator 304 of the aerosol supply system 100 described above.

[0143] The aerosol generator 304 comprises an aerosol generating layer 330, also known as an aerosolizable layer. The aerosol generating layer 330 comprises an aerosol generating material 302. The aerosol generator 304 also comprises a resistance heating layer 340. In embodiments, the resistance heating layer 340 is formed as a conductive layer. The aerosol generating layer 330 is located on the resistance heating layer 340. The aerosol generating layer 330 is in direct contact with the resistance heating layer 340. In embodiments, the aerosol generating layer 330 is in indirect contact with the resistance heating layer 340. In embodiments, the resistance heating layer 340 may include a coating. As will be described in detail below, the resistance heating layer 340 includes a plurality of resistance heating elements 342, for example, as shown in Figures 8 and 9. Each resistance heating element or each resistance heating element 342 forms at least a portion of a conductive path between a pair of electrical contacts 322. Each resistance heating element or each resistance heating element 342 provides a conductive path for resistance heating at least a portion of the aerosol generating material 302 to generate an aerosol. In embodiments, the aerosol generating material 302 is in the form of a film or a gel.

[0144] The resistance heating layer 340 is formed as a conductive layer. In this embodiment, this layer takes the form of at least one of a metal layer such as an aluminum layer or a non-metallic material such as graphene. The resistance heating layer 340 is in the form of a foil, for example, an aluminum foil.

[0145] The aerosol generator 304 comprises a support 350. In this embodiment, the support 350 includes paper or card material. The support 350 provides structural support for the aerosol generator 304. The resistance heating layer 340 is located on the support 350. The support 350 is configured as a support layer. As shown in Figure 7, in the aerosol generator 304, the resistance heating layer 340 is sandwiched between the support 350 and the aerosol generation layer 330.

[0146] The support 350 is electrically insulating. The resistance heating layer 340 and the support layer 350 define the substrate 352. The substrate 352 supports the aerosol generating layer 330. In this embodiment, the substrate 352 is defined solely by the resistance heating layer 340.

[0147] The substrate 352 has a first surface 353 on which the resistance heating element 342 is located. The substrate has a second surface 355 on which the heater electrical contacts 322 are located. The first substrate surface 353 and the second substrate surface 355 are opposite each other and define the opposite surface of the substrate 352 as a panel. The aerosol generating layer 330 is on the first surface 353. In embodiments, for example as shown in Figures 2 to 4, the electrical track extends across a small percentage of the second surface, for example less than 10%, optionally less than 20%, optionally less than 50%. In embodiments, for example as shown in Figure 26, the heater electrical track extends across substantially the entire second surface, for example more than 90%. The article 300 may comprise a laminate 354 including a resistance heating layer 340 and a support layer 350. In embodiments, the laminate 354 includes an aerosol generating layer 330. The aerosol-generating layer 330 may be formed as a continuous structure or from individual parts. The individual parts may include one or more of the following shapes: dots, strips, helices, or other shapes.

[0148] One or more of the aerosol generation layer 330, the resistance heating layer 340, and the support layer 350 may include further layers. For example, the support layer 350 may include a backing layer or an intermediate layer. The support layer 350 is omitted in this embodiment.

[0149] Figure 8 shows one of the resistance heating elements 342. The resistance heating layer 340 comprises a plurality of resistance heating elements 342. In this embodiment, the resistance heating layer 340 comprises a single resistance heating element 342.

[0150] Multiple heating elements 342 may be formed in an array 344 as shown in Figure 9. Other configurations are also possible.

[0151] The resistive heating element 342 comprises a resistive heating path. The resistive heating path is formed by a conductive path. The resistive heating path is nonlinear. The resistive heating path is spiral. The configuration of the resistive heating path may vary. The electrical resistance of the heating element 342 may depend on the properties of the resistive heating path in the conductive layer, such as the length, width, thickness, and arrangement of the path. The electrical resistance of the resistive heating path may also depend on the material in which the resistive heating path is formed.

[0152] The resistive heating element 342 extends between a first type of electrical contact 360 and a second type of electrical contact 365. The first type of electrical contact 360 is configured to provide a positive contact, and the second type of electrical contact 365 is configured to provide a negative contact. Current flows through the path between the first type of electrical contact 360 and the second type of electrical contact 365. The contact arrangement may be reversed. The first type of electrical contact 360 and the second type of electrical contact 365 constitute the heater electrical contact 322. The first type of electrical contact 360 and the second type of electrical contact 365 form at least a portion of the article electrical contact configuration 320.

[0153] The meandering or winding nature of the path of the resistive heating element 342 is such that the electrical resistance of the path increases compared to a straight path between the first and second types of electrical contacts.

[0154] The resistance heating layer 340 may include a first type of electrical track 361 extending from the resistance heating element 342. The first type of electrical track 361 includes a first type of electrical contact 360. The first type of electrical contact 360 is configured to electrically connect to the device electrical connector 230. The first type of electrical contact 360 includes a first type of exposed contact area 362. The first type of exposed contact area 362 is exposed on the article for direct connection to the device electrical connector 230.

[0155] The resistance heating layer 340 may include a second type of electrical track 366 extending from the resistance heating element 342. The second type of electrical track 366 includes a second type of electrical contact 365. The second type of electrical contact 365 is configured to electrically connect to the device electrical connector 230. The second type of electrical contact 365 includes a second type of exposed contact area 367. The second type of exposed contact area 367 is exposed on the article 300 for direct connection to the device electrical connector 230.

[0156] As will be discussed in detail below, the conductive path of the resistive heating element 342 in the embodiment is created by defining at least one electrically insulating barrier 346 within the resistive heating layer 340. In the embodiment, the electrically insulating barrier 346 is formed by cutting barrier limiting portions (i.e., electrically insulating portions), such as gaps, channels, or slots, into a sheet formed of the conductive material to form the resistive heating layer 340. In the embodiment, the conductive element 342 is pre-formed to define the resistive heating element or each resistive heating element 342 and then applied to the support 350. In the embodiment, the resistive heating layer 340 is applied to the support 350 and then the resistive heating element or each resistive heating element 342 is defined within the resistive heating layer 340. The resistive heating element or each resistive heating element 342 defining the resistive heating layer 340 may be a printed heater.

[0157] At least one electrical insulating barrier 346 defines first and second types of electrical tracks 361, 366.

[0158] The insulating barrier may be a void. In this embodiment, the insulating barrier is, for example, a filled void filled with an insulating material. The barrier defines a barrier against electrical conduction across the barrier.

[0159] The resistance heating elements defining the resistance heating layer 340, or each resistance heating element 342, may be formed by a cutting operation. Cutting may include die cutting. The resistance heating elements may be formed by an operation applied only to the resistance heating layer. In embodiments, the resistance heating elements may be formed by an operation applied to both the resistance heating layer and the support layer, for example, by an operation that cuts the resistance heating layer and the support layer.

[0160] In some embodiments, the tracks of the resistive heating element or each resistive heating element 342 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 a gap 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 resistive heating element or each resistive heating element 342 may have overall dimensions of approximately 10 mm × 10 mm. Other dimensions are possible in other exemplary embodiments. By forming resistive heating elements or each resistive heating element 342 of these dimensions from aluminum foil with a thickness of 0.006 mm and an electrical resistivity of 2 to 6 μOhm cm, the resistance of the path has been calculated to be approximately 1 Ohm. In one exemplary embodiment, the resistance was measured at 0.83 to 1.31 Ohm.

[0161] As shown in Figure 9, the resistance heating layer 340 may be formed of a plurality of resistance heating elements generally indicated by reference numbers 342a, 342b, 242c, 342d, and 342e. Each of the resistance heating elements 342a to 342e extends from each of the first type of electrical contacts generally indicated by reference numbers 360a, 360b, 360c, 360d, and 360e to a single second type of electrical contact 365. Each of the resistance heating elements 342a to 342e is at least each portion of the respective conductive path between each of the first type of electrical contacts 360a to 360e and the second type of electrical contact 365. Each of the resistance heating elements 342a to 342e is configured to heat at least each portion of the aerosol generating material 302 disposed thereon. The number of electrical contacts may vary. Therefore, each resistive heating element 342a to 342e extends between individual first-type electrical contacts and common second-type electrical contacts.

[0162] Each of the resistance heating elements 342a to 342e provides a conductive path for resistance heating a portion of the aerosol generating material 302 in order to generate an aerosol in each part of the aerosol generator 304.

[0163] The distinct first types of electrical contacts 360a to 360e allow current to be supplied individually to each of the multiple resistive heating elements 342a to 342e. This allows for control of heating in different zones of the aerosol generation layer 330. For example, an aerosol generator may have five aerosol generation zones. The resistive heating layer 340 allows each of these zones to be operated separately. Thus, for example, five aerosol aspirates may be produced from a single consumable incorporating a single aerosol generator 304, or ten aerosol aspirates may be produced from a single consumable incorporating two aerosol generators 304.

[0164] In an exemplary resistive heating layer 340, a plurality of first-type electrical contacts 360a to 360e, e.g., positive electrical connections, and a single second-type electrical contact 365, e.g., a negative electrical connection, are provided. The resistive heating elements 342a to 342e share a common negative terminal. This is not essential for all implementations. For example, a plurality of second-type contacts may be provided. In the embodiment, each resistive heating element 342a to 342e includes a corresponding first-type electrical contact 360 and a corresponding second-type electrical contact 365.

[0165] In the embodiment of the resistive heating layer 340 shown in Figure 9, the first type of electrical contacts 360a to 360e are located on the first edge 363 of the resistive heating layer 340, and the second type of electrical contacts 365 are located on the second edge 368 of the resistive heating layer 340. This allows for convenient power connection, but of course, many other configurations are possible, some of which will be discussed further below.

[0166] Figure 10 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, generally referred to as reference number 400, according to an exemplary embodiment.

[0167] The method or algorithm 400 begins with an operation 402 in which a resistive heating layer is formed on one or more heating elements (e.g., multiple heating elements), each resistive heating element extending from a first type of electrical contact to a second type of electrical contact. In use, the heating elements or each heating element may be used to provide a conductive path for resistively heating a portion of an aerosol-generating material to generate an aerosol. The formation of the resistive heating elements or each resistive heating element may be performed before or after applying the resistive heating layer on a support, if a support is present. The resistive heating layer may be bonded to the support, or mounted or formed on the support in a different configuration.

[0168] In operation 404, the formed resistance heating layer is positioned in contact with the aerosol generating layer, which incorporates an aerosol generating material. The aerosol generator 304 described above can be generated using algorithm 400.

[0169] Figure 11 shows an aerosol generator 304 formed according to one embodiment. The aerosol generating material 302 is formed on the resistance heating layer 340, for example by spraying, painting, dispensing, or by depositing the aerosol generating material in some other way. In an exemplary implementation of operation 64, the aerosol generating layer 330 is disposed on the resistance heating layer 340 as indicated by arrow 406.

[0170] Figure 12 shows a resistance heating layer 340 formed according to an exemplary embodiment. The resistance heating layer 340 is in the process of being cut using a laser cutter 408. Cutting the resistance heating layer 340 can be used to form the paths for the heating elements described herein. The use of a laser cutter 408 (or any other cutting process) is not the only way in which the resistance heating layer 340 described herein can be produced. Several exemplary methods are described below.

[0171] Figure 13 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, which is generally referred to as reference no. 410. The method or algorithm 410 begins with operation 412, in which a resistance heating layer is provided. In operation 414, one or more resistance heating elements are formed within the resistance heating layer by chemical etching of the resistance heating layer. Operations 412 and 414 are exemplary implementations of operation 402 of method 400 described above. An aerosol generating material is then placed on the resistance heating layer, thereby implementing operation 404 described above.

[0172] Figure 14 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, which is generally referred to as reference no. 418. The method or algorithm 418 begins with operation 420, in which one or more heating elements are formed by printing a resistance heating layer, at least partially. Thus, operation 420 is an exemplary implementation of operation 62 of algorithm 402 described above. The aerosol generating material is then placed on the resistance heating layer, thereby implementing operation 404 described above.

[0173] The cutting, etching, and printing methods described above are provided as examples, and other additional or alternative methods are also possible. For example, a so-called “hot foil” method can be used, in which the heating element is fabricated from a resistance heating layer and then assembled / bonded onto a support. Even further techniques such as die cutting can also be used. Furthermore, two or more techniques can be combined (for example, conductivity can be added to the connection trace by adding more conductive materials such as additional foil, printing material, etc.). Those skilled in the art will recognize many further techniques or combinations of techniques that can be used in the implementation forms of the principles described herein.

[0174] Figure 15 is a flowchart illustrating an exemplary embodiment of an operating method or algorithm, collectively referred to as reference no. 424. The method or algorithm 424 may be implemented, for example, using one of the aerosol generators described herein. The method or algorithm 424 is initiated when a command to activate heating is received in an instance of operation 426. In response to the command to activate heating, a determination is made as to whether a heating element is available (operation 428). Multiple heating elements may be provided, as discussed above. Operation 428 may involve determining which heating element has been used and / or whether the corresponding available aerosol-generating material has been exhausted.

[0175] If heating elements are available, the algorithm proceeds to operation 430, where the available heating elements are used. As discussed above, heating elements may be individually controllable, for example, by supplying power to individual heating elements. Once operation 430 is complete, the algorithm terminates with operation 432. If, in operation 428, it is determined that no heating elements are available, for example, because all heating elements have been used, the algorithm terminates with operation 432. This may mean that the consumable parts used to implement algorithm 424 need to be replaced.

[0176] Figure 16 shows a resistance heating layer 340 formed according to an embodiment. The resistance heating layer 340 is cut using a laser cutter 408, but other methods such as chemical etching or printing may also be used, as discussed above. The cuts in the conductive layer 340 form heating elements as described herein.

[0177] In the embodiment shown in Figure 16, the path to be cut is a straight path extending along the length of the conductive layer 120.

[0178] Figure 17 shows another embodiment of the resistance heating layer 340. The resistance heating layer 340 can be formed using the laser cutter 408 described above, or some similar device or other method. The resistance heating layer 340 comprises a plurality of resistance heating elements 342, each resistance heating element 342 being a linear heating element with a conductive path extending along the length of the resistance heating layer 340. Each resistance heating element 342 extends from one of a first type of electrical contact 360, e.g., a positive electrical connection, to one of a second type of electrical contact 365, e.g., a negative electrical contact. In such embodiments, both types of electrical contacts are located at the same end of the resistance heating layer 340 and are adjacent to each other. In configurations where there is no common second type of electrical contact, as in some other embodiments, each heating element instead has separate first and second types of electrical contacts.

[0179] Figure 18 shows another embodiment of the resistance heating layer 340. The resistance heating layer 340 can be formed using the laser cutter 408 described above, or some similar device or other method. The resistance heating layer 340 comprises a plurality of heating elements 342, each heating element 342 being a linear heating element with a conductive path extending along the length of the resistance heating layer 340. Each resistance heating element 342 extends from one of a first type of electrical contact 360, e.g., a positive electrical connection, to a second type of electrical contact 365, e.g., a negative electrical contact. In such embodiments, different types of electrical connections are provided at both ends of the resistance heating layer 340, and a common second type of electrical contact is provided. While a linear path is provided, an increase in electrical resistance may be provided by providing a notched path that functions as a helical path. Note that the paths of any other embodiments described herein may also be notched.

[0180] Figure 19 shows the distal end of article 300. As shown, the body 324 includes a plurality of body layers 325. The body layers 325 are arranged in a laminate of body layers 325. The body layers 325 form a laminate. In this embodiment, the body layers 325 are card layers. Other suitable materials may be used. The body layers 325 are configured to define the features of article 300. In this embodiment, at least one body layer includes a gap that defines an air inlet 315. The gap defines an opening 314.

[0181] The aerosol generator 304 includes a resistance heating layer 340. The resistance heating layer 340 includes resistance heating elements 342, a first type of electrical contact 360 that provides, for example, a positive electrical connection to each of the multiple heating elements 342, and a single second type of electrical contact 365 that provides, for example, a common negative electrical connection to the multiple heating elements 342. The first type of electrical contact 360 and the second type of electrical contact 365, i.e., the heater contact 322, together form at least a portion of the article electrical contact configuration 320 of the aerosol generator 304.

[0182] The resistive heating element 342 is located inside the resistive heating layer 340. The inside defines the first side 306 of the aerosol generator 304, as shown in Figure 3. The heater contact 322 is located on the second side 307 of the resistive heating layer 340. The second side 307 defines the outside of the aerosol generator 304. The heater contact 322 is exposed so as to be able to contact the device electrical connector 230. The heater contact 322 is on the opposite side of the resistive heating layer 340 from the resistive heating element 342. Other configurations are also possible.

[0183] The support layer 350 is located between the inner portion and the outer portion of the resistance heating layer 340.

[0184] A fold 370 is formed in the resistance heating layer 340. The fold 370 defines the heater contact 322. As shown in Figures 2-4 and Figure 19, the fold 370 extends perpendicular to the longitudinal axis of the aerosol generator 304. The fold 370 defines the flap 372. The heater contact 322 is located on the flap 372. The flap defines the contact panel 376. The remaining blank portion defines the heating element panel 375. The resistance heating element 342 is located on the heating element panel 375.

[0185] In embodiments having a support layer 350, the support layer 350 is folded in the embodiment. The base material 352 is folded at the fold 370. In embodiments, the support layer 350 is terminated at the fold. In embodiments, the fold 370 extends parallel to the longitudinal axis of the aerosol generator 304.

[0186] The folded portion of the resistance heating layer 340 is fixed in the folded position. In this embodiment, this folded portion is bonded, for example, by a joint. Other fastening means are also anticipated.

[0187] The fold 370 defines a first type of exposed contact area 362. The fold 370 defines a second type of exposed contact area 367. Electrical tracks 361 and 366 are electrically connected across the fold 370. The heater contacts 322 of the first type of electrical track 361 and the second type of electrical track 366 are defined on the second side of the resistance heating layer 340. Parts of the first type of electrical track 361 and the second type of electrical track 366 extend to the first side of the resistance heating layer 340. In embodiments, the resistance heating element extends from the fold 370. Other configurations are also conceivable.

[0188] The fold 370 defines the end edge 371. The heater contacts 322 of the first type of electrical track 361 and the second type of electrical track 366 extend over the end edge. By providing the fold 370, it is possible to prevent exposed edges, such as the cut edge of the substrate 352, from coming into contact with the connector of the device 200 into which the article 300 is inserted, and thus improve the reliability of the contacts. The fold helps to reduce or prevent damage to the resistance heating layer and / or the substrate during handling, for example, during manufacturing. In embodiments, the device contacts of the device connector may be electrically connected to the end edge. Such arrangement can minimize the thickness of any such device 200.

[0189] As shown in Figure 4, the fold 370 is formed at the end of the aerosol generator 304 perpendicular to the longitudinal axis. The fold 370 is formed between the contact panel 376 and the heating element panel 375. In embodiments described herein with reference to Figures 23-25, for example, the fold 370 extends parallel to the longitudinal axis. In such embodiments, the fold may form a longitudinally extending end edge. In other embodiments, additional panels and folds are defined to form the end edge.

[0190] The aerosol generator 304 comprises multiple connector electrical contacts 232 of an electrical connector 230. The configuration of the device connector 230 depends on the configuration of the heater contacts 322 of the aerosol generator 304. In embodiments such as the aerosol generator shown in Figure 19, the aerosol generator 300 comprises multiple heater contacts 322, including one of a plurality of first type heater contacts 360 and a plurality of second type heater contacts 365. Article 300 includes another set of heater contacts 322 on the opposite side of article 300 corresponding to the second aerosol generator 304.

[0191] Figure 20 shows a device connector 230 of an aerosol supply device 200 used in several embodiments. The connector 230 has separate connector electrical contacts 232 for connection to the heater contacts 322.

[0192] Figure 21 schematically shows the aerosol supply system 100. The system 100 includes article 300 and aerosol supply device 200, both of which are shown in the block diagram. The device 200 comprises a first connector 230a and a second connector 230b.

[0193] Connectors 230a and 230b allow the aerosol supply device 200 to supply a regulated or controlled voltage and / or current to various first-type heater contacts 360 and second-type heater contacts 365 of the aerosol generator 304 when the article 300 is inserted into the aerosol supply device 200. The aerosol supply device 200 may include connector components configured to supply power to connectors 230a and 230b. The aerosol supply device 200 may operate, for example, in the manner described above.

[0194] Figure 22 is a flowchart showing a method or algorithm for forming an aerosol generator 304, generally referred to as reference number 440, according to an exemplary embodiment.

[0195] The method or algorithm 440 begins with operation 442 in which a resistive heating layer is formed on at least one resistive heating element, the heating element or each heating element providing a conductive path for resistive heating at least a portion of the aerosolizable material to generate an aerosol. Exemplary heating elements that may be formed in operation 442 are described elsewhere herein.

[0196] In operation 442, the aerosol-generating material is applied and / or formed on the resistance heating layer.

[0197] Operations 442 and 444 of method or algorithm 440 are similar to (and may be identical to) operations 402 and 404 of method or algorithm 400 described above.

[0198] In operation 446, at least one first type of electrical contact is provided on the resistance heating layer. The method of formation may be any of the methods described above. In operation 448, at least one second type of electrical contact is provided on the resistance heating layer. The method of formation may be any of the methods described above.

[0199] In the embodiment, the first and second types of electrical contacts are formed along or near a single edge of the resistance heating layer. In the embodiment, the first and second types of electrical contacts are formed along or near different edges of the resistance heating layer.

[0200] In the embodiment, a first type of electrical contact (e.g., positive connection(s)) is provided along a first edge of the resistance heating layer. In the embodiment, a second type of electrical contact (e.g., negative connection(s)) is provided along a second edge of the resistance heating layer. Operations 446 and 448 can be performed in different orders or simultaneously. Furthermore, operations 446 and 448 can be performed together with operation 442.

[0201] In operation 450, the resistance heating layer is folded. In an embodiment, the support layer is folded together with the resistance heating layer. In an embodiment, the resistance heating layer is folded such that the first and second types of electrical contacts are adjacent to each other, as will be discussed in detail below.

[0202] Figures 23 to 25 show embodiments of the aerosol generator 304 formed according to algorithm 440.

[0203] Figure 23 shows another embodiment of the formed aerosol generator 304. The resistance heating layer 340 is cut using a laser cutter 408. The pre-folded configuration defines a blank for forming the aerosol generator 304. The blank in the embodiment defines fold lines along which folds are made during the formation of the aerosol generator. The aerosol generator 304 blank includes a resistance heating layer 340 and a support layer 350. The resistance heating layer 340 and the support layer 350 define a panel defined by the fold lines.

[0204] As shown in Figure 23, the resistance heating layer 340 is formed on multiple heating elements 342, but the number may vary, or there may be only one. Multiple first type electrical contacts 360 (e.g., positive electrical contacts) are provided along the first edge of the conductive layer (one contact is shown for each heating element). A single second type electrical contact 365 is provided along the second edge of the resistance heating layer 340. In this embodiment, the contact is spaced apart from the edge. As discussed above, each of the multiple heating elements extends from the first type electrical contact to the second type electrical contact.

[0205] The cuts made by the laser cutter 408 in the resistance heating layer 340 form heating elements or paths for each heating element 342. As discussed above, laser forming or any other cutting process is not the only way to produce the resistance heating layer 340 described above. Some exemplary alternative methods include chemical etching and printing.

[0206] As shown in Figure 24A, the aerosol generating layer 200 is provided on the resistance heating layer 340. Next, the blank is folded as indicated by the arrows in Figure 24A. In this embodiment, these steps are reversed. In this embodiment, the folds are formed parallel to the longitudinal direction of the aerosol generator 304. Two folds are formed. The first fold 370 is formed between the heating element panel 375 and the first contact panel 376. The first heating element panel 375 is defined to include a heating element 342. The first contact panel 376 is formed, having a plurality of first type electrical contacts 360. The second contact panel 377 is formed, having second type electrical contacts 365. The second fold 378 is formed between the heating element panel 375 and the second contact panel 377. The aerosol generating layer 330 is on the heating element panel 375. The aerosol generating layer 330 is absent from the fold or each fold.

[0207] In some embodiments, only one of the first contact panel 376 and the second contact panel 377 is present. In some embodiments, only one of the first fold line 370 and the second fold line 378 is present. In other words, only one of the first contact panel 367 and the second contact panel 377 is folded back.

[0208] Referring to Figure 24B, for example, an embodiment of an aerosol generator including a single fold is shown. The fold is defined by a fold line 370. The fold line 370 is formed in the conductive layer 340. The fold line defines the heating element 342 on the heating element panel 375. The fold line extends parallel to the longitudinal axis of the aerosol generator. The fold line 370 defines the contact panel 376, which has first type electrical contacts 360 and second type electrical contacts 365. The remainder of the blank defines the heating element panel 375. The fold line 370 in the embodiment is predetermined. The fold line extends perpendicular to the longitudinal direction, but other arrangements are also expected. The fold line is linear. The contact panel 376 has multiple first type electrical contacts 360 and second type contacts 365. As shown, there is a single second type electrical contact 365. In this embodiment, there are multiple second-type electrical contacts 365. As shown in the figure, each of the multiple first-type electrical contacts 360 and second-type contacts 365 is located on a contact panel 376. In this embodiment, at least one of the multiple first-type electrical contacts 360 and second-type contacts 365 is located on a heating element panel 375. The contact panel 376 defines the electrical contact area. In this embodiment, there is a single electrical contact area. By utilizing a single fold, it may be easier to align the article contacts with the device contacts. Manufacturing of the device and article may also be easier because the accumulation of tolerances may be reduced.

[0209] Figure 25 shows a schematic perspective view of the heating element side of the folded aerosol generator 304. The electrical track extends from the first side of the aerosol generator 304 where the heating element 342 is located to the second side where the electrical contacts 360 and 365 are located.

[0210] Figures 26 to 31 show another embodiment of the aerosol generator. Since this aerosol generator has substantially the same features as the embodiment of the aerosol generator described above, a detailed description is omitted. The features of the embodiment described above are also applicable to the embodiment described below, and vice versa. In the aerosol generator arrangement shown in Figure 26, the substrate 352 is folded around a first fold 370 and a second fold 378, with a heating element panel 375 defining the first panel layer, and a first contact panel 376 and a second contact panel 377 defining the second panel layer. The first and second panel layers extend parallel to each other.

[0211] Figure 27 is a view of the distal end of the aerosol generator 304 shown in Figure 26. The aerosol generators in Figures 26 and 27 are substantially the same as aerosol generators 23-25, but in this embodiment, an end fold 384 is formed to define the terminal edge 371.

[0212] The first type of electrical contact 360 and the second type of electrical contact 365 extend onto the second substrate surface 355. In this arrangement, the connection or contact point with the power source 220 can be located on the second substrate surface 355, spaced apart from the resistance heating element 342.

[0213] The electrical contact areas of the first type of electrical contact 360 and the second type of electrical contact 365 are separated from the resistance heating element 342. The electrical contact areas of the first type of electrical contact 360 and the second type of electrical contact 365 do not overlap with the resistance heating element 342. This arrangement helps reduce damage to the resistance heating element 342 in use because the most likely locations for sparks and short circuits, i.e., contact points with the power source 220, are separated from and / or spaced apart from the resistance heating element. Furthermore, because the aerosol generating layer 330 is deposited on the resistance heating element, this arrangement makes it possible to position the electrical contacts away from the airflow channels for carrying the aerosol generated from the aerosol generating layer. This helps improve the quality of the aerosol delivered to the user because obstructions in the airflow channels are minimized. The corresponding folded arrangements in Figures 2-4 and Figure 19, for example, may also help provide such advantages.

[0214] In the embodiment, the first type of electrical contact 360 and the second type of electrical contact 365 extend to positions on a second surface adjacent to each other, as shown, for example, in Figure 26. This may be due to the pre-set sizes of the first type of electrical contact 360 and / or the second type of electrical contact 365, or the pre-set sizes of the first contact panel 376 and the second contact panel 377. Preferably, this allows for a reduction in the size of the electrical connector 230 in the aerosol supply device 200, as the distance between the first type of electrical contact 360 and the second type of electrical contact 365 tends to be reduced and / or minimized. Furthermore, providing two longitudinal fold lines minimizes the number of exposed cut edges defining the edges of the aerosol generator 304. These will be discussed in more detail below in relation to Figure 28.

[0215] The first type of electrical contact 360 and the second type of electrical contact 365 each extend to the terminal edge 371 of the aerosol generator 304. The terminal edge 371 extends perpendicular to the longitudinal direction.

[0216] The end edge 371 is defined by an end fold 384, which is described in detail below. The end fold 384 allows the device electrical connector 230 to be positioned at the bottom of the receptacle of the aerosol supply device 200. Preferably, this helps to provide a more stable connection between the electrical contacts and the device connector 230. The end fold may help to prevent damage to the substrate. In embodiments, neither of the first nor second types of electrical contacts extends longitudinally to the end longitudinal edge of the aerosol generator.

[0217] The distal end of the aerosol generator is shown in Figure 27. An end fold 384 defining the end edge 371 is shown. The end fold 384 forms a flap structure 385 of the resistance heating layer 340 (see Figure 28). In the arrangement with two longitudinal folds, two flaps define the flap structure, which is defined by the end fold 340. In the arrangement with a single longitudinal fold, a single flap defines the flap structure, which is defined by the end fold 340. The flaps of the flap structure 385, or each flap, are sandwiched between a first panel layer, i.e., the heating element panel layer, and a second panel layer, i.e., the contact panel layer. Such an arrangement ensures that there are no exposed cut edges at the end edge 371. The end fold 384 defining the end edge 371 helps to increase the exposed contact area. The fold at the end helps to create a chamfered edge at the end edge 371.

[0218] One or more folds in the longitudinal end edge 380 help provide rigidity and structural integrity due to the additional material layer. End folds 384 provide an additional layer within the stack of layers at the end edge to help increase the rigidity of the end edge. Thus, damage or deformation to the aerosol generator tends to be reduced or eliminated. This damage or deformation can be a problem when inserting the aerosol generator into an aerosol supply device. Preferably, folds tend to help reduce damage and / or deformation when handling the aerosol generator, for example, when inserting the aerosol generator and / or articles formed therefrom into an aerosol supply device. Furthermore, the edges of layers without folds, for example, cut edges, tend to have exposed particles / fibers and may be prone to fraying. For example, resistance heating layers, if their edges are not folds, for example, cut edges, may delaminate at the edges from the underlying support layer. Again, this is likely to occur when inserting the aerosol generator into an aerosol supply device. Preferably, the fold moves the fragile edge away from the end edge of the aerosol generator 304, thereby reducing or eliminating the risk of the end edge fraying. Furthermore, in an article or aerosol supply device housing such an aerosol generator 304, the flap may be positioned between the resistive heating element and the outer surface defined on the article or aerosol supply device. In these arrangements, the fold and / or flap may provide an insulating layer that acts as thermal insulation. Such insulation operates between the outer surface and the resistive heating element, thereby minimizing heat transfer to the user.

[0219] Figures 28 to 31 show the formation of an aerosol generator from a blank 388. The blank is formed from a substrate 352. The blank 388 is formed and supplied from a substrate construct. In this embodiment, the blank 388 defines a heating element panel 375, a first contact panel 376, and a second contact panel 377. These panels substantially correspond to the panels discussed above. The blank 388 further comprises a flap construct 385. The blank 388 includes a core panel 389. The core panel 389 is omitted in some embodiments. In some embodiments, the core panel 389 may be located adjacent to the first contact panel 376. In other words, the first contact panel 376 is positioned between the core panel 389 and the heating element panel 375. In these embodiments, the core panel 389 is electrically coupled to each of the first type of electrical contacts. Therefore, the core panel 389 provides a contact test area for testing the resistance of each of the first type of electrical contacts during manufacturing. The core panel 389 can then be folded after testing. No further processing is required to minimize the impact of the core panel 389 on the function of the final aerosol generator 304. In other embodiments, the core panel 389 is provided adjacent to the second contact panel 377 such that the second contact panel 377 is positioned between the core panel 389 and the heating element panel 375. Preferably, these arrangements allow for the efficient provision of a contact test area. In other words, a contact test area can be provided without significantly adding components and / or involving significant complexity, such as processing the contact test area.

[0220] The blank 388 further defines a first contact panel fold line 370a that extends longitudinally over the first type of electrical contact 360. The first contact panel fold line 370a is located between the heating element panel 375 and the first contact panel 376. When the resistance heating layer 340 is folded around the first contact panel fold line 370a, the first contact panel fold 370 extends longitudinally. The first contact panel fold 370 defines the first longitudinal edge of the aerosol generator. The first type of electrical track 361 extends from the first side to the second side via the first contact panel fold 370.

[0221] The blank further comprises a second contact panel fold line 378a extending longitudinally over the second type of electrical contact 365. When the resistance heating layer 340 is folded around the second fold line 378, the second contact panel fold 378 extends longitudinally. The second contact panel fold 378 defines the second longitudinal edge of the aerosol generator. The second type of electrical track 366 extends from the first surface to the second surface via the second contact panel fold 377.

[0222] The heating element panel 375 has a distal end 375a. The first and second contact panels 376 each extend beyond the distal end 375a of the heating element panel.

[0223] The first and second contact panels 376 define an end fold 384. The end fold 384 is defined by an end fold line. The end fold 384 is formed to define the end edge 371. The end fold 384 corresponds to the distal end 375a of the heating element panel 375.

[0224] The end fold 384 forms a flap structure 385 of the resistance heating layer 340. The first flap 385a and the second flap 385b define the flap structure 385, which is defined by the end fold 340.

[0225] The first contact panel 376 includes a first fold line portion 394a of the end fold 384. The first fold line portion 394a extends along the direction defined by the distal end 375a. Thus, the end fold 384 defines a first flap 385a. The first flap 385a formed by the end fold is sandwiched between the heating element panel layer and the contact panel layer when the aerosol generator 304 is formed. The first fold line portion 394a defines at least partially the end edge 371 of the aerosol generator 304.

[0226] The second contact panel 377 further comprises a second fold line portion 396a of the end fold 384. The second fold line portion 396a extends along the direction defined by the distal end 375a. The second flap 385b formed by the second fold line portion 396a is sandwiched between the heating element panel layer and the contact panel layer when the aerosol generator 304 is formed. The second fold line portion 396a at least partially defines the end edge 371 of the aerosol generator. Furthermore, the first fold line portion 394a and the second fold line portion 396a are combined to define the end edge 371 of the aerosol generator 382. In this embodiment, the end fold includes a single fold defining a single flap.

[0227] The blank 388 further comprises a support fold line 390, which is positioned between the heating element panel 375 and the core panel 389. Folding the resistance heating layer 340 around the core fold line 390 forms a core positioned between the first and second sides of the aerosol generator 360. In this way, the core is located beneath the heating element panel (and the resistance heating element on it) and the electrical contact panel (and the electrical contacts on it). Preferably, such a core ensures a consistent thickness of the aerosol generator. Furthermore, such a core also provides additional support for the heating element and / or electrical contacts. Similar to the flap discussed above in relation to Figure 27, the core provides an additional insulating layer between the resistance heating element and the outer surface. In some embodiments, the core fold line 390 may be omitted.

[0228] In some methods for manufacturing the aerosol generator, the blank 388 may be folded around the core fold line 390 such that the support panel 389 is below the heating panel 375. In other methods, this step may be omitted entirely.

[0229] Referring here to Figure 29, after the support panel is folded, the blank 388 is folded around the contact panel fold lines 394a and 396a, forming end folds 384, respectively. In other words, folding around the fold lines 394a and 396a results in the formation of end folds 384. The fold line portions 394 and 396 define the electrical contact areas of both the first type of electrical contact 360 and the second type of electrical contact 365. Similarly in this case, the third fold 394 and / or the fourth fold 396 have the advantages described above in relation to the end folds 384. In embodiments, this step can be performed before / without folding the support panel.

[0230] Referring here to Figure 30, after folding around the third contact panel fold line 370a and the fourth contact panel fold line 378a, the blank 388 is further folded around the first contact panel fold line 370a and the second contact panel fold line 378a to form the first fold line 370 and the second fold line 378, respectively. This causes the first contact panel 376 and the second contact panel 377 to at least partially define the second surface and / or the second panel layer. This also results in the first type of electrical track 361 and the second type of electrical track 366 extending from the first surface to the second surface, and the first type of electrical contact 360 and the second type of electrical contact 365 being positioned on the second surface. This provides the advantages discussed above. In embodiments, this step can be carried out before or without any of the steps described above.

[0231] Referring here to Figure 31, following folding around the first contact panel fold line 370a and the second contact panel fold line 378a, the base structure 396 of the aerosol generator 304 is provided. The aerosol generating layer 330 can be deposited on the resistance heating element 342 of the base structure 388. Once the aerosol generating layer 330 is deposited on the resistance heating element 342, the aerosol generator 304 is provided.

[0232] In the embodiment, different arrangements are possible. For example, in the embodiment, the flap structure 385 extends from the longitudinal end of the heating element panel 375, similar to the arrangement shown in Figure 2. The flap of the flap structure is folded so as to be parallel to the heating element panel 375. In such an arrangement, the electrical track is arranged to pass directly from the heating element panel 375 through the flap. The first panel 376 and the second panel 377 described above as contact panels, or a single panel with a single longitudinal fold in the aerosol generator 304, do not have an electrical track and function as a cover panel. The flap of the flap structure is sandwiched between the first panel 376 and the second panel 377 and the heating element panel 375. Thus, the path of the electrical track can be minimized. In a variation of such an embodiment, a first type of electrical contact may be formed on a flap structure 385 that extends directly from the heating element panel 375 and is defined by a fold line perpendicular to the longitudinal direction, and a second type of electrical contact may be formed on a contact panel defined by a fold line parallel to the longitudinal direction. In such an arrangement, the first and second types of contacts are spaced apart from each other.

[0233] In the embodiment, the fold lines defining the contact panel may be end fold lines extending perpendicular to the longitudinal direction, and the fold lines forming the end edge may extend parallel to the longitudinal direction. Such an arrangement provides the end edge along the longitudinal range of the aerosol generator 304.

[0234] Figure 32 shows a flowchart of a method 400 for manufacturing an aerosol generator. In step 402, a first type of electrical contact 360 of the aerosol generator is formed. For example, this may involve chemically or laser etching a layer of conductive material. The layer of conductive material may be deposited on a support layer. The support layer may be a sheet material such as paper or cardboard. Additionally or alternatively, step 402 may include printing the conductive material on the support layer or on the aerosol generating layer. The forming step 402 may also involve any of the techniques discussed above, such as the techniques discussed in relation to Figures 12, 13, and 16. In embodiments, the forming step 402 involves forming a plurality of first type of electrical contacts 360. The conductive material may be aluminum or any other conductive metal or metal alloy.

[0235] In step 404, a second type of electrical contact 365 of the aerosol generator is formed. The second type of electrical contact may be formed using any of the techniques discussed in relation to the formation of the first type of electrical contact. In other words, the description of step 402 also applies to the formation of the second type of electrical contact 365. In embodiments, the step 365 to be formed involves forming a plurality of second type electrical contacts 365.

[0236] In step 406, a resistance heating element 342 is formed on the resistance heating layer 340. The resistance heating element 342 is formed to be at least a portion of the conductive path between the first type of electrical contact 360 and the second type of electrical contact 365. The resistance heating element 342 may be formed using any of the techniques discussed in relation to the formation of the first type of electrical contact. The forming step 406 may involve forming multiple resistance heating elements 342. Each of these may form its own conductive path between each first type of electrical contact 360 and each second type of electrical contact 365 or a common second type of electrical contact 365.

[0237] In step 408, an aerosol generating layer 330 containing the aerosol generating material 302 may be deposited on the resistance heating layer 340 so that the resistance heating element 342 can heat at least a portion of the aerosol generating material 302 to generate an aerosol.

[0238] In step 410, one of the first type of electrical contact 360 and the second type of electrical contact 365 is folded such that the fold defines the electrical contact area of ​​at least one of the first type of electrical contact 360 and the second type of electrical contact 365. One or more of the steps discussed above in relation to any of Figures 28 to 31 may be part of the folding step 410.

[0239] The order of steps shown in Figures 28 and 32 is illustrative only. In embodiments, the various steps may be performed in any order, or any of the steps may be performed simultaneously with one or more of the other steps. The number of steps shown in Figures 28 and 32 is also illustrative only. In embodiments, any of the steps may be omitted.

[0240] In the embodiment, the support layer defining the first and / or second type of electrical contacts is also folded. In the embodiment, the support layer defining the first and / or second type of electrical contacts is foldless, and for example, the heating element layer extends beyond the support layer and folds around the support layer.

[0241] In the above embodiment, none of the fold lines are pre-formed in the blank. In other embodiments, one or more fold lines are pre-formed in the blank, for example, folds, or indentations, or notches, or any other weakening of the electrical contacts and / or the supporting layer in contact therewith.

[0242] In some embodiments of the aerosol generators and different arrangements of articles described above, the aerosol-generating material is formed in a configuration other than as an aerosol-generating layer. In embodiments, the aerosol-generating material is in the form of an aerosol-generating segment. An aerosol-generating segment generally comprises a solid material. Such a solid material may be shredded tobacco. For example, an 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 tobacco material pieces. In embodiments, the aerosol-generating material comprises a plurality of strips, beads, or pellets. In embodiments, the aerosol-generating segment is a mass of material.

[0243] In the embodiments, the aerosol-generating segment includes a material body. The aerosol-generating material is non-liquid. In such embodiments, the material body includes 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 cut 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 reconstituted tobacco.

[0244] The aerosol-generating material, formed as a solid material, may contain nicotine. The aerosol-generating material may contain tobacco, be made from tobacco, or be essentially made from tobacco. In some embodiments, the aerosol-generating material does not contain tobacco.

[0245] 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 mass of material. The article may comprise a mouthpiece end section. A tubular element may be positioned between the aerosol-generating material and the mouthpiece end section. The article may comprise a ventilation area in the mouthpiece end section. The mouthpiece end section may define a mouthpiece configured to be positioned between the user's lips.

[0246] In any embodiment of the article described above, a resistance heating element or each resistance heating element is configured to heat substantially the entire aerosol-generating material. The aerosol-generating segment in the embodiment is at least substantially cylindrical. In the embodiment, the aerosol-generating segment is at least partially enclosed by a resistance heating layer. In the embodiment, the resistance heating element extends within the aerosol-generating segment. The resistance heating element may extend around the aerosol-generating segment. In the embodiment, the resistance heating element surrounds the aerosol-generating segment. In some arrangements, 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 the embodiment, a first type of electrical contact and a second type of electrical contact are exposed from the aerosol-generating segment.

[0247] The aerosol-generating material may include tobacco materials such as those described herein, which include tobacco components. In the tobacco materials described herein, the tobacco components may include paper-reconstructed tobacco. The tobacco components may also include loose-leaf tobacco, extruded tobacco, and / or band-cast tobacco. The tobacco material may be provided in the form of cut rag tobacco. Cut rag tobacco can be formed from a mixture of forms of tobacco materials, for example, a mixture of one or more of paper-reconstructed tobacco, loose-leaf tobacco, extruded tobacco, and band-cast tobacco. In embodiments, the tobacco material includes paper-reconstructed tobacco, or a mixture of paper-reconstructed tobacco and loose-leaf tobacco. In the tobacco materials described herein, the tobacco material may include filler components. Filler components are generally components that do not contain non-tobacco components, i.e., raw materials derived from tobacco. Filler components may be non-tobacco fibers such as wood fibers or pulp or wheat fibers. Filler components may also be inorganic materials such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, and magnesium carbonate. Filler components may also be non-tobacco cast materials or non-tobacco extruded materials. Filler components 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, filler components are absent. In the tobacco materials described herein, the tobacco material contains an aerosol-forming agent material. In this context, “aerosol-forming agent material” is an agent that promotes aerosol formation. Aerosol-forming agent materials may promote aerosol formation by promoting the initial vaporization and / or condensation of gas into inhalable solid and / or liquid aerosols. In some embodiments, aerosol-forming agent materials may improve the delivery of flavor from the aerosol-forming material. In general, any suitable aerosol-forming agent material, including those described herein, may be included in the aerosol-forming material of the present invention.

[0248] Paper-reconstructed tobacco refers to tobacco material formed by a process in which tobacco raw materials are extracted with a solvent to obtain an extract of soluble substances and a residue containing fibrous material, and then the extract (usually after concentration and optionally after further processing) is recombined with fibrous material from the residue (usually after purification of the fibrous material and optionally with the addition of some non-tobacco fibers) by depositing the extract onto the fibrous material. The recombination process is similar to the process of making paper.

[0249] 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. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably 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, wherein the aerosol generating material is located on the resistance heating layer, The first type of electrical contact, The second type of electrical contact, A fold in the resistance heating layer for defining at least one of the electrical contact regions of the first type of electrical contact and the second type of electrical contact, Equipped with, An aerosol generator in which 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.

2. The aerosol generator according to claim 1, wherein at least one of the first type of electrical contact and the second type of electrical contact extends from the fold.

3. The aerosol generator according to claim 1, wherein the first type of electrical contact and the second type of electrical contact extend from the fold.

4. The aerosol generator according to any one of claims 1 to 3, wherein the fold defines the electrical contact region of at least one of the first type of electrical contact and the second type of electrical contact extending from the fold.

5. The aerosol generator according to any one of claims 1 to 4, wherein the aerosol generator is elongated, defines a longitudinal axis, and the fold extends along an axis perpendicular to the longitudinal axis.

6. The aerosol generator according to claim 5, wherein the fold defines the longitudinal end of the aerosol generator.

7. The aerosol generator according to any one of claims 1 to 4, wherein the aerosol generator is elongated, defines a longitudinal axis, and the fold extends along an axis parallel to the longitudinal axis.

8. The aerosol generator according to any one of claims 1 to 7, wherein the fold is a first fold defining the first type of electrical contact, and also comprises a second fold, the second fold defining the second type of electrical contact.

9. The aerosol generator according to any one of claims 1 to 8, wherein the fold defines the terminal edge of the aerosol generator.

10. The aerosol generator according to any one of claims 1 to 9, wherein the resistance heating layer includes a heating element panel having the resistance heating element and a contact panel having at least one of the first type of electrical contact and the second type of electrical contact, and the fold is located between the heating element panel and the contact panel.

11. The aerosol generator according to claim 10, wherein the fold is a first fold and also comprises a second fold, and the first fold extends perpendicularly to the second fold to define an end fold.

12. The aerosol generator according to claim 11, wherein the first fold defines the flap.

13. The aerosol generator according to claim 12, wherein the flap is sandwiched between the heating element panel and the contact panel.

14. An aerosol generator according to any one of claims 1 to 13, comprising an aerosol generating layer incorporating the aerosol generating material, wherein the aerosol generating layer is located on the resistance heating layer.

15. An aerosol generator according to any one of claims 1 to 14, comprising a support layer, wherein the resistance heating layer is located on the support layer, and each of the resistance heating layer and the support layer is folded at the fold.

16. An article comprising an aerosol generator according to any one of claims 1 to 15.

17. An aerosol generator according to any one of claims 1 to 15 or an aerosol supply device configured to receive an article according to claim 16.

18. Aerosol generation system, The article described in claim 16, an aerosol supply device configured to receive the aforementioned article, An aerosol generation system equipped with the following features.

19. A blank for forming an aerosol generator, A resistance heating layer comprising a resistance heating element configured to generate an aerosol by heating at least a portion of an aerosol generating material on the resistance heating layer, The first type of electrical contact, The second type of electrical contact, Fold lines in the resistance heating layer for defining at least one of the first type of electrical contact and the second type of electrical contact region, Equipped with, A blank in which 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.

20. A method for manufacturing an aerosol generator, The steps include preparing a resistance heating layer, The steps include forming a first type of electrical contact in the aerosol generator, The steps include forming a second type of electrical contact in the aerosol generator, A step of forming a resistance heating element on the resistance heating layer, wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact; The steps include folding the resistance heating layer along a fold line to form a crease that defines an electrical contact area of ​​at least one of the first type of electrical contact and the second type of electrical contact, Methods that include...

Images