aerosol generator

Abstract

An aerosol generator (304) is provided. The aerosol generator comprises an aerosol generating material (302), a resistance heating layer (340) configured to heat the aerosol generating material, and a support layer (350) having a support. The resistance heating layer is located on a first side of the support. The resistance heating layer comprises at least one of a first type of electrical contact and at least one of a second type of electrical contact. At least one of the first type of electrical contact and the second type of electrical contact is accessible from a second side of the support.

Description

Technical Field

[0001] The present invention relates to an aerosol generator for an article for an aerosol supply device. The present invention also relates to an article for an aerosol supply device, 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 create tobacco smoke by burning tobacco during use. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combustion. Examples of such products are so-called "non-combustion heating" products, or tobacco heating devices or products, that release compounds by heating a material without burning it. 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 create an aerosol from a suitable medium, which is then 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 creating an aerosol from a suitable medium.

Summary of the Invention

[0004] According to one embodiment, an aerosol generator for an article for an aerosol supply device is provided, the aerosol generator comprising: an aerosol generating material; a resistance heating layer comprising a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol, wherein the aerosol generating material is located on the resistance heating layer; a first type of electrical contact; 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; and a support, wherein the resistance heating layer is located on the first side of the support between the aerosol generating material and the support, and at least one of the first type of electrical contact and the second type of electrical contact is accessible from the second side of the support.

[0005] 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.

[0006] In any of the above embodiments, the resistance heating layer does not include folds.

[0007] In any of the above embodiments, the support does not have folds.

[0008] In any of the above embodiments, the support comprises a support layer.

[0009] In any of the above embodiments, the support is electrically insulating.

[0010] In any of the above embodiments, the support comprises paper or card.

[0011] In any of the above embodiments, the conductive layer and the support layer define the substrate.

[0012] In any of the above embodiments, the aerosol generator comprises a laminate having a resistance heating layer and a support layer.

[0013] In any of the above embodiments, the laminate includes an aerosol-generating material.

[0014] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact is accessible from the second side of the support.

[0015] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact is exposed from the second side of the support.

[0016] In any of the above embodiments, the support layer comprises a card layer.

[0017] In any of the embodiments described above, the second side is on the opposite side of the first side.

[0018] In any of the above embodiments, 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.

[0019] In any of the embodiments described above, the support defines the exposed contact area of ​​the first type of electrical contact.

[0020] In any of the embodiments described above, the exposed contact area is a first exposed contact area, the support defines a second exposed contact area, and the second exposed contact area is an exposed contact area of ​​a second type of electrical contact.

[0021] In any of the above embodiments, the aerosol generation layer is a continuous aerosol generation layer.

[0022] In any of the above embodiments, the aerosol generation layer is a discontinuous aerosol generation layer.

[0023] In any of the above embodiments, the aerosol generation layer comprises a plurality of individual aerosol generation portions.

[0024] In any of the above embodiments, the resistive heating element is one of a plurality of resistive heating elements.

[0025] In any of the above embodiments, one of the individual aerosol generation portions is associated with a corresponding one of the plurality of resistive heating elements.

[0026] In any of the above embodiments, the aerosol generation layer comprises at least one of dots, strips, and patches.

[0027] In any of the above embodiments, the resistive heating element is a first heating element, the resistive heating layer forms a second resistive heating element, and each resistive heating element provides a conductive path for resistively heating a portion of the aerosol-forming material to generate an aerosol at a respective portion of the aerosol generation layer.

[0028] In any of the above embodiments, the resistive heating layer forms an array of resistive heating elements comprising at least a first resistive heating element and a second resistive heating element.

[0029] In any of the above embodiments, each of the first type of electrical contact and the second type of electrical contact is configured to enable current to be supplied individually to each of the resistive heating elements.

[0030] In any of the above embodiments, the aerosol generation layer comprises a film or gel layer containing an aerosol-forming material.

[0031] In any of the above embodiments, the aerosol generator comprises a plurality of first type of electrical contacts, and each heating element comprises a separate first type of electrical contact.

[0032] In any of the embodiments described above, the aerosol generator comprises a plurality of second-type electrical contacts, and each of the resistance heating elements comprises a separate second-type electrical contact.

[0033] In any of the above embodiments, the aerosol generator comprises a single second type of electrical contact.

[0034] In any of the embodiments described above, a single second type of electrical contact is shared between each of the resistance heating elements.

[0035] In any of the above embodiments, the resistance heating element is formed by at least one of the following: cutting the resistance heating layer, chemically etching the resistance heating layer, forming or pressurizing the resistance heating layer within a substrate, or printing the resistance heating layer.

[0036] In any of the above embodiments, the resistance heating layer is in the form of a foil.

[0037] In any of the above embodiments, the aerosol generator has an opening in the support such that at least one of the first type of electrical contact and the second type of electrical contact is accessible from the second side of the support.

[0038] In any of the above embodiments, the opening is provided within the support.

[0039] In any of the above embodiments, the opening is a cutout within the support.

[0040] In any of the above embodiments, the opening extends from the edge of the support.

[0041] In any of the above embodiments, the support comprises a first surface and a second surface.

[0042] In any of the embodiments described above, the opening extends between the first surface and the second surface of the support.

[0043] In any of the above embodiments, the opening is configured to receive at least a portion of the device connector of the aerosol supply device.

[0044] In any of the embodiments described above, each of the first type of electrical contact and the second type of electrical contact is configured to be connected to a device electrical connector.

[0045] In any of the embodiments described above, the support defines an exposed contact area of ​​at least one of the first type of electrical contact and the second type of electrical contact.

[0046] In any of the embodiments described above, the support defines separate exposed contact areas for each of the first type of electrical contact and the second type of electrical contact.

[0047] In any of the embodiments described above, the opening defines a common opening between at least two exposed contact areas of at least one of the first type of electrical contact and the second type of electrical contact.

[0048] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact extends at least partially through the support.

[0049] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact extends at least partially through the support and is exposed on the second side of the support.

[0050] In any of the above embodiments, the aerosol generator includes a path within the support through which at least one of the first type of electrical contact and the second type of electrical contact extends.

[0051] In any of the embodiments described above, the path comprises an opening through a support, and at least one of the first type of electrical contact and the second type of electrical contact extends around the side wall of the opening.

[0052] In any of the above embodiments, the opening extends through the resistance heating layer.

[0053] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact extends around the edge of the opening.

[0054] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact extends partially through the support.

[0055] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact extends entirely through the support.

[0056] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact extends beyond the second side of the support.

[0057] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact includes a conductive coating.

[0058] In any of the above embodiments, the conductive coating includes a conductive ink.

[0059] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact overlaps the second side of the support.

[0060] According to one embodiment, an article is provided that comprises an aerosol generator according to any of the embodiments described above.

[0061] According to one embodiment, an aerosol supply system is provided comprising an aerosol generator according to any of the above embodiments and an aerosol supply device configured to receive the aerosol generator.

[0062] According to one embodiment, an aerosol supply system is provided, comprising an article of any of the above embodiments and an aerosol supply device configured to receive the article.

[0063] According to one embodiment, a method is provided for forming an aerosol generator of an article for an aerosol supply device, the method comprising the steps of: providing a resistance heating layer; providing an aerosol generating material on the resistance heating layer, wherein the resistance heating layer comprises a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; providing a first type of electrical contact; providing 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; providing a support; and providing a resistance heating layer on a first side of the support between the aerosol generating material and the support, wherein at least one of the first type of electrical contact and the second type of electrical contact is accessible from a second side of the support.

[0064] In any of the above embodiments, the method includes the step of providing an aerosol-generating layer containing an aerosol-generating material.

[0065] In any of the embodiments described above, the method includes the step of forming an opening in the support such that at least one of the first type of electrical contact and the second type of electrical contact is accessible from a second side of the support.

[0066] In any of the above embodiments, the step includes forming at least one of the first type of electrical contact and the second type of electrical contact so as to extend at least partially through the support.

[0067] According to one embodiment, an aerosol supply system is provided, comprising an article and an aerosol supply device configured to receive at least a portion of the article, wherein the article comprises an aerosol generating material and a resistance heating layer comprising a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol, the aerosol generating material being on the resistance heating layer, a first type of electrical contact and a second type of electrical contact, the resistance heating element forming at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact, and a support, wherein the resistance heating layer is on the first side of the support between the aerosol generating material and the support, and at least one of the first type of electrical contact and the second type of electrical contact is accessible from the second side of the support.

[0068] 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.

[0069] In any of the above embodiments, the aerosol supply device includes a device electrical connector configured to connect to at least one of a first type of electrical contact and a second type of electrical contact.

[0070] In any of the embodiments described above, the device electrical connector comprises a connector electrical contact configured to connect from a second side of a support to at least one of a first type electrical contact and a second type electrical contact.

[0071] In any of the above embodiments, the device electrical connector comprises a puncture element configured to puncture a feature portion of an article.

[0072] In any of the above embodiments, the feature portion of the article comprises a support, and the puncture element is configured to puncture the support to make electrical contact with at least one of a first type of electrical contact and a second type of electrical contact.

[0073] In any of the above embodiments, the connector electrical contacts include a puncture element.

[0074] In any of the embodiments described above, the puncture element is a pin.

[0075] In any of the embodiments described above, the puncture element is configured to penetrate the resistance heating layer to contact at least one of the first type of electrical contact and the second type of electrical contact.

[0076] In any of the above embodiments, the puncture element is configured to penetrate the support in order to contact at least one of the first type of electrical contact and the second type of electrical contact.

[0077] In any of the embodiments described above, the aerosol supply device comprises a receptacle configured to accept at least a portion of an article, and the connector electrical contacts are located within the receptacle.

[0078] In any of the embodiments described above, the receptacle is configured to position at least one of the first type of electrical contact and the second type of electrical contact.

[0079] In any of the above embodiments, the puncture element includes a conductive material.

[0080] In any of the embodiments described above, the puncture element is movable to engage with the article.

[0081] In any of the embodiments described above, the article is movable to engage with the puncture element.

[0082] In any of the embodiments described above, the puncture element supplies power to the resistance heating layer.

[0083] According to one embodiment, a blank is provided for forming an aerosol generator for an article for an aerosol supply device, comprising: a resistance heating element configured to heat at least a portion of an aerosol generating material to generate an aerosol; a first type of electrical contact; a second type of electrical contact, wherein the resistance heating element forms at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact; a support, wherein the resistance heating layer is located on the first side of the support between the aerosol generating material and the support; and an opening in the support such that at least one of the first type of electrical contact and the second type of electrical contact is accessible from the second side of the support.

[0084] In any of the above embodiments, the blank comprises an aerosol-generating layer containing an aerosol-generating material.

[0085] According to one embodiment, an aerosol generator for an article for an aerosol supply device is provided, the aerosol generator 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 article is provided that comprises an aerosol generator according to any of the embodiments described above.

[0087] According to one embodiment, an aerosol supply system is provided comprising an aerosol generator according to any of the above embodiments and an aerosol supply device configured to receive the aerosol generator.

[0088] Next, various embodiments will be described as mere examples, with reference to the attached schematic drawings. [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 system shown in Figure 1. [Figure 6] Figure 2 is a schematic partially exploded perspective view of the article, showing the aerosol generator inverted from its assembled orientation and spaced apart from other components. [Figure 7] Figure 3 is a schematic cross-sectional view of another aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 8] Figure 3 is a schematic plan view of the heating element of the aerosol generator. [Figure 9] This is a schematic plan view of the resistance heating layer of the aerosol generator shown in Figure 3, which has 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 is a schematic plan view of the first side of the article aerosol generator. [Figure 24] This is a schematic cross-sectional view of an aerosol generator for an article. [Figure 25] Figure 24 is an exploded view of a schematic cross-sectional view of the aerosol generator for the item shown. [Figure 26] This is a schematic cross-sectional view of an aerosol generator for an article. [Figure 27] This is a schematic diagram of the aerosol supply system. [Figure 28] Figure 26 is an enlarged view of the aerosol supply system. [Modes for carrying out the invention]

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

[0091] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating constituent materials (or components thereof) of 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 e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[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 one or more aerosol-generating materials that can be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[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 a consumable receiving area, an aerosol generator, an aerosol generating 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, the term “aerosol-generating material” (which may also be referred to herein as “aerosolizable material”) refers to 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] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, wherein the plant substance is tobacco.

[0104] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components thereof, derivatives, or extracts, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0105] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components thereof, derivatives, or extracts, the plant substances being selected from rooibos and fennel.

[0106] In some embodiments, the substance delivered includes a fragrance.

[0107] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavor components extracted from tobacco. In some embodiments, the flavoring includes flavor components extracted from cannabis.

[0108] In some embodiments, the fragrance may include a sensory stimulant, which is usually chemically induced and intended to achieve somatosensation perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the olfactory or gustatory nerves, and may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable thermal agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol (WS-3).

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

[0110] The aerosol-generating material may include 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.

[0111] The aerosol-generating material may include an aerosol-generating film, or may be in the form of an aerosol-generating film. The aerosol-generating film may include 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.

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

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

[0114] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more individual parts or regions of 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.

[0115] In some embodiments, the aerosol-generating material comprises a plurality of aerosol-generating films. In some embodiments, the aerosol-generating film includes a plurality of aerosol-generating film regions. Such plurality of aerosol-generating films and / or plurality of aerosol-generating film regions may have different properties, such as different compositions, thicknesses, densities, active substances and / or flavors, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0116] 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.

[0117] The slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0118] 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, inside. 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.

[0119] 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, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

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

[0121] The material may be present on or within a support to form a substrate. The support may be, for example, paper, cardboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may comprise these materials.

[0122] An aerosol supply device can accept an article containing an aerosol-generating material for heating. In this context, “article” refers to a component that contains, or is contained at the time of use, an aerosol-generating material that 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.

[0123] 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.

[0124] 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 comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol transfer component, an aerosol-generating area, a housing, packaging paper, a mouthpiece, a filter and / or an aerosol modifier. Consumables may also comprise 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 a conductor that can be heated by the passage of an electric current through it.

[0125] A non-combustible aerosol supply system may comprise a modular assembly that includes both a reusable aerosol supply device and interchangeable aerosol products. In some implementations, the non-combustible aerosol supply device may comprise a power supply and a controller (or control circuit). The power supply 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.

[0126] 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). The article 300 removed from the aerosol supply device 200 is shown in Figure 2. The aerosol generator 304 of the article 300 is shown in Figure 3 along with 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.

[0127] Article 300 comprises 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.

[0128] The aerosol supply system 100 is elongated and extends along its longitudinal axis. The aerosol supply system 100 has a proximal end 102 that is closest to the user (e.g., the user's mouth) when used by the user to inhale the aerosol generated by the aerosol supply system 100, and a distal end 104 that is furthest from the user when used.

[0129] The proximal end may also be called the “mouth end.” Thus, the aerosol delivery system 100 also defines a proximal direction, which is directed toward the user during use. Furthermore, the aerosol delivery system 100 similarly defines a distal direction, which is directed away from the user during use. The terms proximal and distal, applied to the features of the 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.

[0130] Article 300 is received by an aerosol supply device 200. The configuration of article 300 and the aerosol supply device 200 may vary. In this embodiment, the aerosol supply device 200 comprises a device body 202. The device has a housing 204 that encloses the components of the device 200. The device chamber 206 is configured to receive a portion of article 300, as shown in Figure 5. The proximal end 308 of the article protrudes from the device 200 when article 300 is received into the device chamber 206. A receptacle 208 defines the chamber 206. The receptacle 208 comprises a receptacle base 210 and a receptacle peripheral wall 212. The configuration of the receptacle 208 may vary depending on the configuration of article 300.

[0131] One or more user-operable control elements 224, such as buttons or switches, may be provided on the aerosol supply device 200 that can be used to operate the aerosol supply system 100. For example, a user may activate the system 100 by pressing a control element 224. One or more user-operable control elements may be omitted. In some embodiments, the aerosol supply system 100 is operated by another user action, such as a puff activated by the user drawing air through the system.

[0132] The aerosol supply device 200 has an opening 214 at its proximal end that leads into the device chamber 206. The opening 214 is provided at one end, and an article 300 can be inserted through this opening. In some embodiments, the article 300 may be fully or partially inserted into the device 200. The configuration of the device 200 may vary; for example, the opening may be located within 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 some embodiments, the device 200 defines a mouthpiece. The user places their mouth over the mouthpiece during use.

[0133] 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.

[0134] The aerosol supply device 200 includes a power supply 220. The power supply 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.

[0135] As will be discussed in detail below, the heating system 110 is configured to heat the aerosol-generating material 302 of article 300. In various embodiments, article 300 is a consumable and interchangeable with other articles 300. The heating system 110 comprises an aerosol generator 304. The heating system 110 comprises article 300 and other components of the aerosol supply system 100, including components of the aerosol supply device 200, such as a power supply 220 and a control circuit 222.

[0136] The aerosol generator 304 forms part of the article 300. The aerosol generator 304 includes a heating component 312 configured to heat at least one of the aerosol-generating material 302, such as a film and a gel, in order to generate an aerosol. The aerosol-generating material may also be called an aerosolizable material.

[0137] The heating element 312 is a resistive heating element. The resistive heating element comprises a plurality of heating elements, as described below. Each heating element is a resistive heating element, as described in detail below. In such an arrangement, the heating system 110 comprises a resistive heating generator which includes components for heating the heating element 312 by a resistive heating process. In this case, a current is applied directly to the resistive heating element, and the heating element is heated by Joule heating due to the resulting current flow within the heating element which acts as a heating component. The resistive heating element includes a resistive material configured to generate heat when a suitable current passes through the resistive material, and the heating element 312 comprises electrical contacts for supplying current to the resistive material. The provision of the resistive heating element 312 enables a compact configuration. Resistive heating provides an efficient configuration.

[0138] 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 some 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 article at the aerosol outlet 318, as indicated by arrow 319. In some embodiments, the aerosol outlet 318 is located within the mouthpiece of the article 300 so that the aerosol is drawn directly from the article 300 to the user's mouth of the system 100.

[0139] In some exemplary embodiments, an aerosol supply system comprises two main components: a control section forming a reusable portion and a consumable section forming a replaceable or disposable portion, which may be called a replaceable or disposable article or cartridge. As described herein, the aerosol supply device 200 forms the control section, and the article 300 forms the consumable section. In the use of the aerosol generation system, the control section and the consumable section may be releasably connected at an interface. The consumable section may be removable and replaceable, for example, when the consumable section is used, and the control section is reused with another consumable section.

[0140] 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 into the air inlet of the control section, passes through the interface, and exits the consumption section.

[0141] As schematically shown in Figure 5 and described in detail below, article 300 has article electrical contact configuration 320. In various embodiments, the electrical contact configuration 320 is formed by the 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.

[0142] 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 within the internal space. In some embodiments, the internal space comprises two or more chambers.

[0143] The air inlet 314 includes an opening 315. The opening 315 is formed within the main body 324. In some embodiments, the opening is formed within another component of the article 300, such as an aerosol generator 304 or another wall mechanism. The aerosol outlet 318 includes an outlet opening 317. The outlet opening 317 is formed within the main body 324. In some embodiments, the outlet opening 317 is formed within another component of the article 300, such as an aerosol generator 304 or another wall feature.

[0144] As shown in Figure 6, article 300 comprises 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 some embodiments, article 300 comprises 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 some embodiments.

[0145] The aerosol generator or each aerosol generator 304 and the main body 324 are formed in a layered configuration. In some embodiments, other structures such as tubular structures of articles are envisioned. In such tubular structures, the aerosol generator 304 defines a tubular structure. The tubular shape may include a circular cross-section and other polygonal shapes.

[0146] In various embodiments, as shown in the figures, article 300 has a flat configuration. That is, the outer surface 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 conceivable.

[0147] Figure 6 is a partially exploded perspective view of article 300, inverted from its assembled orientation and shown in a spaced-out relationship with other components. Article 300 comprises a first aerosol generator 302, a body 324, and a second aerosol generator. The body 324 separates the first and second aerosol generators 304. The first and second aerosol generators 304 close off 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 area. In some embodiments, one or more of the first and second aerosol generators 304 and the body 324 have a greater length and / or width. In some embodiments, one of the first and second aerosol generators 304 is replaced by a blank panel. The body 324 comprises a body layer. The body may comprise multiple body layers. The body layers are formed within a stack and may be arranged to define feature parts of the article 300, such as an air inlet 314 and an aerosol outlet 318.

[0148] The wrap 390 surrounds the article 300 and forms part of the article 300; see, for example, Figure 25. The wrap 390 is a sheet. The wrap 390 functions as a fixing sleeve. The aerosol generator or each aerosol generator 304 protrudes from the wrap 390 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 the short longitudinal surface or edge of the article 300.

[0149] 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.

[0150] The aerosol generator 304 comprises an aerosol generating layer 330, also known as an aerosolizable layer. The aerosol generating layer 330 contains an aerosol generating material 302. The aerosol generator 304 also comprises a resistance heating layer 340, which in some embodiments 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 some embodiments, the aerosol generating layer 330 is in indirect contact with the resistance heating layer 340. In some embodiments, the resistance heating layer 340 may include a coating. As will be described in detail below, the resistance heating layer 340 comprises 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 the 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 various embodiments, the aerosol generating material 302 is in the form of a film or a gel.

[0151] The resistance heating layer 340 is formed as a conductive layer. In various embodiments, 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.

[0152] The aerosol generator 304 comprises a support 350. In various embodiments, 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.

[0153] 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.

[0154] Article 300 comprises a laminate 354 having a resistance heating layer 340 and a support layer 350. In some embodiments, the laminate 354 comprises an aerosol generating layer 330. The aerosol generating layer 330 may be formed as a continuous structure or from separate parts. The separate parts may comprise one or more of dots, strips, helices, or other shapes.

[0155] In some embodiments, the aerosol-generating layer 330 comprises an aerosol-generating film. In some embodiments, the aerosol-generating layer 330 comprises a plurality of aerosol-generating films. In some embodiments, the aerosol-generating film comprises a plurality of aerosol-generating film regions. Such plurality of aerosol-generating films and / or plurality of aerosol-generating film regions may have different properties, such as different compositions, thicknesses, densities, active substances and / or flavors, one or more aerosol-forming agent materials, and optionally at least one or more other functional materials.

[0156] One or more of the aerosol generation layer 330, the resistance heating layer 340, and the support layer 350 may comprise further layers. For example, the support layer 350 may comprise a backing layer or an intermediate layer. The support layer 350 is omitted in some embodiments.

[0157] Figure 8 shows one of the resistance heating elements 342. The resistance heating layer 340 comprises multiple resistance heating elements 342. In some embodiments, the resistance heating layer 340 comprises a single resistance heating element 342.

[0158] The multiple heating elements 342 are formed in an array 344 as shown in Figure 9. Other configurations are possible.

[0159] The resistive heating element 342 includes a resistive heating path. The resistive heating path is formed as a conductive path. The resistive heating path is nonlinear. The resistive heating path is folded. The configuration of the resistive heating path may be varied. 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.

[0160] A 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 and second types of electrical contacts are heater electrical contacts 322. The first and second types of electrical contacts 360 and 365 form at least a portion of the article electrical contact configuration 320.

[0161] The bending or meandering 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.

[0162] The resistive heating layer 340 includes a first type of electrical track 361 extending from the resistive 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.

[0163] The resistance heating layer 340 includes 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.

[0164] As will be discussed in detail below, the conductive path of the resistive heating element 342 in various embodiments is created by defining at least one electrically insulating barrier 346 within the resistive heating layer 340. In some embodiments, the electrically insulating barrier 346 is formed by introducing an electrically insulating barrier limiting portion (i.e., an electrically insulating portion), such as a gap, channel, or slot, into a sheet formed of a conductive material to form the resistive heating layer 340. In some embodiments, the resistive heating layer 340 is pre-formed to define the resistive heating element or each resistive heating element 342 and then applied to the support 350. In some embodiments, the resistive heating layer 340 is applied to the support 350, and the resistive heating element or each resistive heating element 342 is then 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. The insulating barrier may be an air gap. In some embodiments, the insulating barrier is, for example, a filled gap filled with an insulating material. A barrier defines a barrier to electrical conduction across it.

[0165] The resistive heating elements defining the resistive heating layer 340 or each resistive heating element 342 may be formed by a cutting action. The cutting may include die cutting. The resistive heating elements may be formed by an action applied only to the resistive heating layer. In some embodiments, the resistive heating elements may be formed by an action applied to both the resistive heating layer and the support layer, for example, by an action that cuts the resistive heating layer and the support layer.

[0166] At least one electrical insulating barrier 346 defines first and second types of electrical tracks 361, 366.

[0167] In some embodiments, the tracks of the resistive heating element or each resistive heating element 342 have a width 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 μOhmcm, the resistance of the path is calculated to be approximately 1 ohm. In one exemplary embodiment, the resistance was measured between 0.83 and 1.31 ohms.

[0168] As shown in Figure 9, the resistive heating layer 340 is formed on multiple resistive heating elements, collectively referred to as reference numbers 342a, 342b, 242c, 342d, and 342e. Each of the resistive heating elements 342a to 342e extends from one of the first type electrical contacts, collectively referred to as reference numbers 360a, 360b, 360c, 360d, and 360e, to a single second type electrical contact 365. The number of electrical contacts may vary. Thus, each resistive heating element 342a to 342e extends between individual first type electrical contacts and a common second type electrical contact.

[0169] 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.

[0170] The separate first types 360a-360e of electrical contacts allow current to be supplied individually to each of the multiple resistive heating elements 342a-342e. This allows for control of heating of different zones of the aerosol generation layer 330. For example, the aerosol generator may have five aerosol generation zones. The resistive heating layer 340 allows each of these zones to be activated individually. Thus, for example, five aerosol puffs may be produced from a single consumable incorporating a single aerosol generator 304, or ten aerosol puffs may be produced from a single consumable incorporating two aerosol generators 304.

[0171] 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., negative electrical connection) are provided. This is not essential for all implementations. For example, multiple second-type contacts could be provided. In various embodiments, each resistive heating element 342a to 342e comprises one corresponding to a first-type electrical contact 360 and one corresponding to a second-type electrical contact 365.

[0172] In the embodiment of the resistance 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 resistance heating layer 340, and the second type of electrical contacts 365 are located on the second edge 368 of the resistance heating layer 340. This allows for convenient power connections, but of course, many other configurations are possible, some of which will be discussed further below.

[0173] Figure 10 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, generally denoted by reference numeral 400, according to an exemplary embodiment.

[0174] Method or algorithm 400 begins with 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. When 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.

[0175] In operation 404, the formed resistance heating layer is positioned to be in contact with the aerosol generating layer, and the aerosol generating layer incorporates an aerosol generating material.

[0176] 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 by depositing the aerosol generating material, for example, by spraying, painting, extruding, or some other method. In an exemplary implementation of operation 404, the aerosol generating layer 330 is disposed on the resistance heating layer 340 as indicated by arrow 406.

[0177] 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. The cutting of the resistance heating layer 340 can be used to form the path of the heating element described herein. The use of the 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.

[0178] Figure 13 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, generally indicated by reference numeral 410. The method or algorithm 410 begins in operation 412, where a resistive heating layer is provided. In operation 414, one or more resistive heating elements are formed within the resistive heating layer by chemical etching of the resistive heating layer. Operations 412 and 414 are exemplary implementations of operation 402 of method 400 described above. The aerosol generating material is then placed on the resistive heating layer, thereby performing operation 404 described above.

[0179] Figure 14 is a flowchart illustrating part of a method or algorithm for forming an aerosol generator 304, generally indicated by reference numeral 418. The method or algorithm 418 begins with operation 420, in which one or more heating elements are finally partially formed by printing a resistance heating layer. Thus, operation 420 is an exemplary implementation of operation 402 of algorithm 400 described above. The aerosol generating material is then placed on the resistance heating layer, thereby performing operation 404 described above.

[0180] The cutting, etching, and printing methods described above are provided as examples. Other additional or alternative methods are also possible. For example, a so-called "thermal foil stamping" approach can be used, in which the heating element is fabricated from a resistive heating layer and then assembled / bonded onto a support. Yet another technique, 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 or printing material). Those skilled in the art will recognize many further techniques, or combinations of techniques, that can be used in implementations of the principles described herein.

[0181] Figure 15 is a flowchart illustrating an exemplary embodiment of an operating method or algorithm, collectively referred to as reference numeral 424. The method or algorithm 424 may be carried out, for example, using one of the aerosol generators described herein. The method or algorithm 424 is initiated when a command to initiate heating is received within a fraction of an instant of operation 426. In response to the command to initiate heating, a decision is made as to whether a heating element is available (operation 428). Multiple heating elements may be provided, as discussed above. Operation 428 may include a decision as to which heating element was used and / or whether the corresponding available aerosol generating material has been exhausted.

[0182] If heating elements are available, the algorithm proceeds to operation 430, where 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 heating elements are unavailable, for example, because all heating elements have been used, the algorithm terminates with operation 432. This may mean that the consumable parts used to perform algorithm 424 need to be replaced.

[0183] Figure 16 shows a resistance heating layer 340 formed according to one embodiment. The resistance heating layer 340 is cut using a laser cutter 408, but other methods such as chemical etching or printing can also be used, as discussed above. The cutting of the conductive layer 340 forms the heating element described herein.

[0184] 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.

[0185] Figure 17 shows another embodiment of the resistance heating layer 340. The resistance heating layer 340 may 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 conduction path extending along the length of the resistance heating layer 340. Each resistance heating element 342 extends from one of the first type of electrical contacts 360, e.g., a positive electrical connection, to one of the second type of electrical contacts 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 arrangements that do not include a common second type of electrical contact, as in some other embodiments, each heating element instead has separate first and second type electrical contacts.

[0186] Figure 18 shows another embodiment of the resistance heating layer 340. The resistance heating layer 340 may 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 conduction 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. Although a linear path is provided, the increase in electrical resistance may be provided by providing a sawtooth path that functions as a convolutional path. It should also be noted that the paths of any other embodiments described herein may also be sawtooth.

[0187] Figure 19 shows the distal end of article 300. As shown, the body 324 comprises a plurality of body layers 325. The body layers 325 are arranged in a stack of body layers 325. The body layers 325 form a laminate. In some embodiments, the body layers 325 are card layers. Other suitable materials may be used. The body layers 325 are configured to define feature portions of article 300. In some embodiments, at least one body layer includes a gap that defines an air inlet 315. The gap defines an opening 314.

[0188] 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 a positive electrical connection to each of the multiple heating elements 342, and a single second type of electrical contact 365 that provides a common negative electrical connection to the multiple heating elements 342. The first and second types of electrical contacts 360, 365, i.e., the heater contacts 322, together form at least a portion of the article electrical contact configuration 320 of the aerosol generator 304.

[0189] The resistive heating element 342 is in contact with the aerosol generating layer 330 on the inner surface 341 of the resistive heating layer 340; see, for example, Figure 24. The resistive heating layer 340 defines at least partially the first side 306 of the aerosol generator 304, as shown in Figure 3. The heater contact 322 is on the outer surface 343 of the resistive heating layer 340; see, for example, Figure 24. The heater contact 322 is exposed on the second side 307 of the aerosol generator 304. The outer surface 343 defines a portion of the second side of the aerosol generator 304. The heater contact 322 is exposed so as to be able to make contact with the device electrical connector 230. The heater contact 322 is exposed on the side of the resistive heating layer 340 opposite to the resistive heating element 342. Other configurations are possible.

[0190] The heater contact 322 is exposed on the side of the support layer 350 opposite to the resistance heating layer 340 itself. The support layer 350 in this embodiment does not have any folds. This helps to simplify the manufacture of the aerosol generator 304.

[0191] The support layer 350 defines a first type exposed contact area 362. The support layer 350 defines a second type exposed contact area 367. The heater contacts 322 of the first type electric track 361 and the second type electric track 366 are exposed on the second side of the resistance heating layer 340. Parts of the first type electric track 361 and the second type electric track 366 extend along the first side of the resistance heating layer 340.

[0192] The aerosol supply device 200 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 accessible heater contacts 322, including one of a plurality of first type heater contacts 360 and one of a 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.

[0193] 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.

[0194] Figure 21 schematically shows the aerosol supply system 100. The system 100 comprises article 300 and aerosol supply device 200, both shown in the block diagram. The device 200 includes first and second connectors 230a and 230b.

[0195] Connectors 230a and 230b allow the aerosol supply device 200 to supply a regulated or controlled voltage and / or current to various first and second types of heater contacts 360, 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.

[0196] Figure 22 is a flowchart showing a method or algorithm for forming an aerosol generator 304, generally denoted by reference numeral 440, according to an exemplary embodiment.

[0197] Method or algorithm 440 begins in operation 442, in which a resistive heating layer is formed on at least one resistive heating element, and the heating element or each heating element provides a conductive path for resistive heating at least a portion of an aerosolizable material to generate an aerosol. Exemplary heating elements that may be formed in operation 442 are described elsewhere in this specification.

[0198] In operation 442, the aerosol-generating material is applied and / or formed on the resistance heating layer 340.

[0199] Operations 442 and 444 of method or algorithm 440 are similar to (or may be identical to) operations 402 and 404 of method or algorithm 400 described above.

[0200] 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.

[0201] The first and second types of electrical contacts may be formed along or near a single edge of the resistance heating layer. The first and second types of electrical contacts may be formed along or near different edges of the resistance heating layer.

[0202] A first type of electrical contact (e.g., a positive connection) may be provided along a first edge of the resistance heating layer. A second type of electrical contact (e.g., a negative electrical connection) may be 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.

[0203] In operation 450, a support 350 is provided. A resistance heating layer 340 is provided on the first side 355 of the support 350 between the aerosol generation layer 330 and the support 350. At least one first type electrical contact 360 and a second type electrical contact 365 are accessible from the second side 356 of the support 350.

[0204] In some embodiments, operation 450 of method 400 includes the step of forming an opening 358 in the support 350 so that at least one of the first type of electrical contact 360 and the second type of electrical contact 365 is accessible from the second side 356 of the support 350 through the opening 358, so that an aerosol generator such as the one described with reference to any embodiment of the aerosol generator described above is formed.

[0205] Method 400 may further include the step of forming at least one of the first type of electrical contact 360 and the second type of electrical contact 365 such that it extends at least partially through the support 350.

[0206] For example, as seen in Figures 7, 23, 24, and 25, the support 350 comprises a first side 355 and a second side 356. The resistance heating layer 340 is located on the first side 355 of the support 350 and between the support 350 and the aerosol generating layer 330. The support 350 comprises a first surface 375 on the first side 355 and a second surface 376 on the second side 356. The second side 356 of the support 350 defines the exposed side of the article 300 when assembled.

[0207] The support 350 and the resistance heating layer 340 do not have folds. The resistance heating layer 340 and the support 350 are planar bodies. In some embodiments, folds are formed in one or both of the support 350 and the resistance heating layer 340. By limiting the folds of the resistance heating layer 340, the resistivity of the characteristic parts of the resistance heating layer 340 can be controlled more reliably.

[0208] The first type of electrical contacts 360 and the second type of electrical contacts 365 are accessible from the second side 356 of the support 350. In some examples, all or some of the multiple first type electrical contacts 360 may be accessible from the second side 356 of the support. Additionally or alternatively, all or some of the multiple second type electrical contacts 365 may be accessible from the second side 356 of the support 350.

[0209] The first type of electrical contact 360 and the second type of electrical contact 365 are exposed from the second side 356 of the support 350. The support 350 defines at least one exposed contact area of ​​the first type of electrical contact 360 or the second type of electrical contact 365. The first side 306 of the aerosol generator 304 is covered by other components of article 300, such as the body 324 of article 300, as schematically shown in Figures 6 and 23.

[0210] "Exposed" is interpreted to mean that the electrical contacts can make electrical contact with another component on the second side 356 of the support 350. Thus, the device electrical connector contacts 232 can be connected to them. The exposed contact area is either a first type exposed contact area 362 or a second type exposed contact area 367. In this example, the support 350 defines separate exposed contact areas for the first type electrical contacts 360 and the second type electrical contacts 365, respectively.

[0211] The first type of electrical contact 360 and the second type of electrical contact 365 are configured to connect to the device electrical connector 230 so that the device 200 can supply power to the resistance heating layer 340. The first type of electrical contact 360 and the second type of electrical contact 365 are configured to connect to the device electrical connector contact 232 to provide an electrical connection between the device 200 and the first type of electrical contact 360 and the second type of electrical contact 365. Current is supplied from the power supply 220 to each of the resistance heating elements 342 via the electrical connection between the device 200 and the first type of electrical contact 360 and the second type of electrical contact 365.

[0212] As shown in Figures 23, 24, and 25, the support 350 includes an opening 358 such that the first type of electrical contacts 360 and the second type of electrical contacts 365 are accessible from the second side 356 of the support 350. The first type of electrical contacts 360 and the second type of electrical contacts 365 are accessible through the support 350. The opening 358 extends between the first surface 375 and the second surface 376 of the support 350. In some embodiments, the opening 358 may be located inside the support 350, and the opening may surround the first type of electrical contacts 360 and the second type of electrical contacts 365, allowing access only from the second surface 376 of the support 350. In some embodiments, the opening 358 may be a cutout of the support 350, which extends from the edge of the support 350 and allows access to the first type of electrical contact 360 and the second type of electrical contact 365 from the side of the support 250 and from the second surface 376 of the support 350. In some embodiments, the opening 358 may be formed together with the support 350 during manufacturing. In some embodiments, the opening 358 may be formed, for example, by drilling, milling, or cutting.

[0213] In various embodiments, the wrap 390 extends over the support 350. As shown in Figure 25, the wrap 390 covers the second surface 376. In such a configuration, the wrap 390 includes a wrap opening 391. The wrap opening 391 is aligned with an opening 358 in the support 350.

[0214] In some embodiments, the wrap 390 comprises multiple layers, and the wrap opening 391 is formed through the multiple layers. In some embodiments, the support 350 comprises a wrap, and / or the wrap functions as the support 350.

[0215] In some embodiments, the opening 358 may be cylindrical, rectangular, or any other shape.

[0216] The opening 358 is configured to receive at least a portion of the device electrical connector 230 so that the device electrical connector 230 is at least partially disposed within the opening 358. Once at least a portion of the device electrical connector 230 is received into the opening 358, the device electrical connector contacts 232 make contact with at least one of the first type of electrical contacts 360 and the second type of electrical contacts 365, as shown in Figures 24 and 25.

[0217] The opening 358 defines a common opening between at least two exposed contact areas, allowing access to both the first type of electrical contact 360 and the second type of electrical contact 365 through the common opening. In some embodiments, the support 350 may have multiple openings 358. The support 350 may have one opening 358 for each of the first type of electrical contact 360 and the second type of electrical contact 365. In some embodiments, the support 350 may have a single opening 358 for all of the first type of electrical contact 360 and a second opening 358 for all of the second type of electrical contact.

[0218] In some embodiments, the openings 358 may be regularly spaced along the support 350. The openings 358 may be spaced along the length of the support 350, i.e., repeated along the longest dimension of the support. The openings 358 may be spaced along the width of the support 350, i.e., repeated along the second longest dimension of the support. In some embodiments, the openings 358 may be located along the sides of the support 350.

[0219] As shown in Figure 26, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends at least partially through the support 350. In some embodiments, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends entirely through the support 350, as shown, for example, in Figure 26. In some embodiments, the first type of electrical contact 360 and the second type of electrical contact 365 extend through the support 350. In some embodiments, the first type of electrical contact 360 and the second type of electrical contact 365 extend entirely through the support 350. By extending at least partially through the support 350, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 is accessible from the second side 356 of the support 350. In some embodiments, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends entirely through the support 350 and is exposed on the second side 356 of the support.

[0220] The support 350 includes a path 380 through which at least one of a first type of electrical contact 360 and a second type of electrical contact 365 extends. The path 380 is formed by an opening 381. In some embodiments, the path 380 is formed by a hole or opening within the support 350. In some embodiments, the opening 381 extends through the support 350 and through the resistance heating layer 340.

[0221] At least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends around at least a portion of the side wall of the opening 381. At least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends around the edge of the opening. In some embodiments, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends only around the side wall of the opening 381, or around the side wall and around at least one of the first and second edges of the opening 381. In some embodiments, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends entirely through the support 350. In some embodiments, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends through the support 350 and beyond the second side 356 of the support 350. In some embodiments, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends entirely through the support 350, beyond the second side 356 of the support, and onto the second surface 376 of the support 350. At least one of the first type of electrical contact 360 and the second type of electrical contact 365 may overlap with the second side 356 of the support 350. In some embodiments, at least one of the first type of electrical contact 360 and the second type of electrical contact 365 extends partially through the support 350.

[0222] At least one of the first type of electrical contact 360 and the second type of electrical contact 365 includes a conductive coating. In some embodiments, the conductive coating may include a conductive ink. The conductive ink is in liquid form when applied, thus making it easier to apply to the path 380, for example, the side walls of the opening, the edges of the opening, and the second surface of the support 350.

[0223] In various embodiments, one or more of the device electrical connector contacts 232 may be attached to at least one of the first type of electrical contact 360 and the second type of electrical contact 365 to provide an electrical connection between the device electrical connector 230 and the resistance heating layer 340. The device electrical connector contacts 232 may be attached to a conductive coating.

[0224] An aerosol supply system 500 is also disclosed. The aerosol supply system comprises an article 300 and an aerosol supply device 200. In various embodiments, the article 300 and the aerosol supply device 200 may be as described above.

[0225] As shown in Figure 27, the device 200 is configured to accept at least a portion of the article 300. The device 200 accepts a portion of the article 300 such that a portion of the article 300 protrudes from the device 200. In some embodiments, the device 200 may accept the entire article 300.

[0226] Article 300 comprises an aerosol generating layer 330 containing an aerosol generating material 302. Article 300 also comprises a resistance heating layer 340, the resistance heating layer comprising a resistance heating element 342 configured to heat at least a portion of the aerosol generating material 302 so that the aerosol generating material 302 generates an aerosol. The aerosol generating layer 330 is located on the resistance heating layer 340. Article 300 also comprises a body 324.

[0227] Article 300 further comprises at least one of the first type of electrical contacts 360 and at least one of the second type of electrical contacts 365. In various embodiments, at least one of the first type of electrical contacts 360 and the second type of electrical contacts 365 may be as described above. The resistance heating element 342 forms a conductive path between the first type of electrical contact 360 and the second type of electrical contact 365.

[0228] Article 300 further comprises a support 350. A resistance heating layer 340 is disposed on a first side 355 of the support 350 so as to be sandwiched between the aerosol generating layer 330 and the support 350. At least one of a first type of electrical contact 360 and a second type of electrical contact 365 is accessible from a second side 356 of the support 350.

[0229] Device 200 includes a device electrical connector 230 that receives power from a power supply 220. In some embodiments, device 200 may include a plurality of device electrical connectors 230. The device electrical connector 230 is configured to connect to at least one of a first type of electrical contact 360 and a second type of electrical contact 365. In some embodiments, the device may include a device electrical connector 230 configured to connect to the first type of electrical contact 360 and a second device electrical connector 230 configured to connect to the second type of electrical contact 365. The device electrical connector 230 includes a device connector electrical contact 232 configured to connect to at least one of the first type of electrical contact 360 and the second type of electrical contact 365. The device connector electrical contact 232 is made of a conductive material.

[0230] The device electrical connector 230 includes a puncture element 240, as seen, for example, in Figures 27 and 28. The puncture element 240 is configured to puncture a feature portion of the article 300. The feature portion includes a support 350. In some embodiments, the feature portion may include the support 350 and a resistance heating layer 340. In some embodiments, the feature portion may include a body 324. In some embodiments, the feature portion may include an aerosol generating layer 330. The puncture element 240 is configured to puncture the support 350 so as to contact at least one of the first type of electrical contact 360 and the second type of electrical contact 365 via the support 350. Thus, the puncture element 240 functions as a device connector electrical contact 232. When contacting at least one of the first type of electrical contact 360 and the second type of electrical contact 365, the puncture element 240 makes electrical contact with at least one of the first type of electrical contact 360 and the second type of electrical contact 365. In various embodiments, each of the device connector electrical contacts 232 is a puncture element.

[0231] The puncture element 240 comprises a pin. The puncture element 240 comprises a conductive material. In some embodiments, the puncture element 240 may also comprise a metal. The puncture element 240 is configured to penetrate the support 350 to contact at least one of the first type of electrical contact 360 and the second type of electrical contact 365. In some embodiments, the puncture element 240 may be configured to penetrate the resistance heating layer 340 to contact at least one of the first type of electrical contact 360 and the second type of electrical contact 365. In some embodiments, each of a plurality of device electrical connectors 230 may comprise a puncture element 240. As shown in Figure 27, the device 200 comprises one puncture element 240 for each of at least one of the first type of electrical contact 360 and at least one of the second type of electrical contact 365. In some embodiments, each puncture element 240 may be configured to be electrically connected to one of the first type of electrical contacts 360 or one of the second type of electrical contacts 365. In some embodiments, each puncture element 240 may be configured to puncture the support 350 so as to contact the first type of electrical contact 360 or the second type of electrical contact 365.

[0232] The device comprises a receptacle 208 configured to receive an article 300. The article 300 is partially received by the receptacle 208 such that at least a portion of the article 300 protrudes from the receptacle. In some embodiments, the article 300 may be fully received by the receptacle 208. Once the article 300 is received by the receptacle 208, the puncture element 240 penetrates the article 300 so that an electrical connection is formed between the puncture element 240 and at least one of the first type of electrical contact 360 and the second type of electrical contact 365.

[0233] The puncture element 240 is movable to puncture and engage with the article 300. The puncture element 240 is positioned on a movable plate 250 disposed within the receptacle 208, and the movable plate 250 is configured to move toward the article 300 relative to the device 200 when the article 300 is accepted into the receptacle 208. The movable plate 250 is disposed within the receptacle perimeter wall 212 or within the receptacle base 210. The movable plate 250 is configured to automatically move toward the article (in direction A) in response to the article 300 being accepted into the receptacle. In some embodiments, the receptacle 208 may further include a sensor configured to detect that the article 200 has been accepted into the receptacle 208. In response to detecting that article 300 has been accepted into the receptacle 208, the sensor may transmit a signal to the processor indicating that article 300 has been accepted into the receptacle 208. In response to receiving the signal, the processor may transmit an actuation signal to an actuator mechanically connected to the movable plate 250. In response to receiving the actuation signal, the actuator moves the movable plate 250 toward the article 300 that has been accepted into the receptacle 208.

[0234] The receptacle 208 includes a pressure plate 260, as shown in Figure 28. When the article 300 is accepted into the receptacle 208, it pushes down the pressure plate 260 (in direction B). The pressure plate 260 is connected to a movable plate 240. In some embodiments, the pressure plate may be mechanically connected to the movable plate 240 by a bar coupling mechanism. The bar coupling mechanism may be configured to transmit the force applied to the pressure plate 260 to the movable plate 250. When the pressure plate 260 is pushed down, the movable plate 250 moves toward the article 300 disposed within the receptacle 208 so that the puncture element 240 engages with the support 350.

[0235] In some embodiments, the device 200 includes a button that functions as a user-operable actuator. Once an article is accepted into the receptacle 208 so that the puncture element 240 engages with the support 350, the user can activate the button to move the movable plate 250 toward the article 300. The button may be electrically connected to a motor configured to actuate the puncture element 240. If the user wishes to remove the article 300 from the receptacle, the user can activate the button again to move the puncture element 240 away from the article 300.

[0236] In various embodiments, a fixing element is provided within the receptacle 208 to secure the article 300 in place when the article 300 is received into the receptacle 208. The puncture element 240 moves toward the fixing element. Once the article 300 is received into the receptacle 208, the movable plate 250 moves toward the fixing element so that the article 300 is sandwiched between the movable plate 250 and the fixing element. The fixing element provides a resistive force against the movement of the movable plate 250 so that the puncture element engages with the support 350.

[0237] In some embodiments, the fixing element is movable. The fixing element moves simultaneously with the movable plate 250 to fix the article 300 in place within the receptacle 208. The fixing element may move in a direction substantially opposite to that of the movable plate 250. The fixing element and the movable plate 250 may be formed as reciprocating jaws. The movable plate 250 and the fixing element may move following the activation of a button by the user as described above, and / or in response to the pressure plate 260 being pressed down as described above.

[0238] In some embodiments, the article 300 may be movable to engage with the puncture element 240. The puncture element 240 may be fixed to the receptacle 208. The puncture element 240 may be disposed on the receptacle base 210 or the receptacle peripheral wall 212. The puncture element 240 may be fixed to the receptacle 208 to puncture the article 300 when the article is accepted into the receptacle 208. The puncture element 240 may extend into the device chamber 206 defined by the receptacle 208. The article 300 may occupy the device chamber 206 when the article 300 is accepted into the receptacle 208. When the article 300 is inserted into the receptacle 208, the article 300 may be pressed against the puncture element 240 so that the puncture element 240 engages with the article 300.

[0239] The puncture element 240 supplies power to the resistance heating layer 340.

[0240] A blank for forming an aerosol generator 304 of article 300 for an aerosol supply device 200 is also disclosed. The aerosol generator 304 may be an aerosol generator 304 described in any of the earlier embodiments. The blank comprises an aerosol generating layer 330 containing an aerosol generating material 302. The aerosol generating material 302 may be in the form of a gel. The blank further comprises a resistance heating layer 340 comprising a resistance heating element 342. The resistance heating element 342 is configured to heat at least a portion of the aerosol generating material 302 to generate an aerosol.

[0241] The resistance heating layer 340 is cut using a laser cutter as previously described. The resistance heating layer 340 is formed on multiple resistance heating elements 342, the number of which may vary, or there may be only one. Multiple first type electrical contacts 360 (e.g., positive electrical contacts) are provided on the conductive layer 340. One or more second type electrical contacts 365 (e.g., negative electrical contacts) are also provided on the resistance heating layer 340. In various embodiments, the contacts are spaced apart from the edges. As discussed above, each heating element of the multiple heating elements 342 extends from the first type electrical contact 360 to the second type electrical contact 365.

[0242] The cutting of the resistance heating layer 340 by the laser cutter 408 forms the heating elements or the paths for each heating element 342. As discussed above, laser formation 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, die cutting, and printing.

[0243] The blank includes a support 350, and the resistance heating layer 340 is located on the first side 355 of the support between the aerosol generating layer 330 and the support 350. The blank has an opening 358 within the support 350 that allows access to at least one of a first type of electrical contact 360 and a second type of electrical contact 365.

[0244] In some embodiments of the different arrangements of the aerosol generator and articles described above, the aerosol-generating material is formed in a configuration other than as an aerosol-generating layer. In various embodiments, the aerosol-generating material is in the form of an aerosol-generating segment. The aerosol-generating segment generally comprises a solid material. Such a solid may be shredded tobacco. For example, the aerosol-generating material arranged as an aerosol-generating segment may comprise a plurality of individual aerosol-generating material pieces. The aerosol-generating material may also comprise individual pieces of tobacco material. In various embodiments, the aerosol-generating material comprises a plurality of strips, beads, or pellets. In various embodiments, the aerosol-generating segment is a plug of material.

[0245] In various embodiments, the aerosol-generating segment includes a body of material. The aerosol-generating material is non-liquid. In such embodiments, the body of material includes a rod of aerosol-generating material, for example, a tobacco rod. For example, the body of material may include shredded tobacco material. The body of material may be formed into a rod. In some embodiments, the body of material 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.

[0246] 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.

[0247] In any of the embodiments described above, heating the article provides a relatively constant release of volatile compounds into an inhalable medium. In the embodiments described above, the aerosol-generating segment is a plug of material. The article may comprise a mouthpiece section. A tubular element may be located between the aerosol-generating material and the mouthpiece section. The article may comprise a ventilation region within the mouthpiece section. The mouthpiece section may define a mouthpiece configured to be placed between the user's lips.

[0248] In any embodiment of the article described above, the resistance heating element or each resistance heating element is configured to heat substantially the entire aerosol-generating material. The aerosol-generating segment in the embodiments is at least substantially cylindrical. In the embodiments, the aerosol-generating segment is at least partially enclosed by a resistance heating layer. In the embodiments, the resistance heating element extends into the aerosol-generating segment. The resistance heating element may extend around the aerosol-generating segment. In the embodiments, 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 embodiments, first type electrical contacts and second type electrical contacts are exposed from the aerosol-generating segment.

[0249] The aerosol-generating material may include tobacco materials 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 some 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 contain 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. The filler component may be present in an amount of 0 to 20% by weight of the tobacco material, or in an amount of 1 to 10% by weight of the composition. In some embodiments, the filler component is absent. In the tobacco material 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 can 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 can improve the delivery of flavor from the aerosol-forming material. In general, any suitable aerosol-forming agent material or agent, including those described herein, may be included in the aerosol-forming material of the present invention.

[0250] 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.

[0251] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may 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. An aerosol generator for an aerosol supply device, wherein the aerosol generator is Aerosol generating materials and A resistance heating layer comprising a resistance heating element configured to heat at least a portion of the aerosol generating material in order to generate an aerosol, The aerosol generating material is located on the resistance heating layer, and the resistance heating layer is located on the resistance heating layer. The first type of electrical contact, A second type of electrical contact, The resistive heating element is at least part of the conductive path between the first type of electrical contact and the second type of electrical contact, A support comprising a support, wherein the resistance heating layer is located on the first side of the support between the aerosol generating material and the support, An aerosol generator in which at least one of the first type of electrical contact and the second type of electrical contact is accessible from a second side of the support.

2. The aerosol generator according to claim 1, wherein the resistance heating layer does not have folds.

3. The aerosol generator according to claim 1 or 2, wherein the support is electrically insulating.

4. An aerosol generator according to any one of claims 1 to 3, comprising an aerosol generating layer containing an aerosol generating material, wherein the aerosol generating layer is located on the resistance heating layer.

5. The aerosol generator according to any one of claims 1 to 4, wherein at least one of the first type of electrical contact and the second type of electrical contact is accessible from the second side of the support.

6. The aerosol generator according to any one of claims 1 to 5, wherein the support has an opening such that at least one of the first type of electrical contact and the second type of electrical contact is accessible from the second side of the support.

7. The aerosol generator according to any one of claims 2 to 6, wherein the opening is configured to receive at least a portion of the device electrical connector of the aerosol supply device.

8. The aerosol generator according to claim 6 or 7, wherein the support defines an exposed contact area of ​​at least one of the first type of electrical contact and the second type of electrical contact.

9. The aerosol generator according to any one of claims 1 to 8, wherein at least one of the first type of electrical contact and the second type of electrical contact extends at least partially through the support.

10. The aerosol generator according to claim 9, wherein at least one of the first type of electrical contact and the second type of electrical contact has a path extending through it within the support.

11. The aerosol generator according to claim 10, wherein the path comprises an opening through the support, and at least one of the first type of electrical contact and the second type of electrical contact extends around the side wall of the opening.

12. The aerosol generator according to claim 11, wherein the opening extends through the resistance heating layer.

13. The aerosol generator according to any one of claims 9 to 12, wherein at least one of the first type of electrical contact and the second type of electrical contact includes a conductive coating.

14. The aerosol generator according to any one of claims 9 to 12, wherein at least one of the first type of electrical contact and the second type of electrical contact overlaps the second side of the support.

15. A method for forming an aerosol generator for an aerosol supply device, wherein the method is The steps include providing a resistance heating layer, A step of providing an aerosol generating material on the resistance heating layer, wherein the resistance heating layer comprises a resistance heating element configured to heat at least a portion of the aerosol generating material in order to generate an aerosol, The steps include providing a first type of electrical contact, The step of providing a second type of electrical contact, The resistive heating element is at least part of the conductive path between the first type of electrical contact and the second type of electrical contact, step, The steps include providing a support, The step of providing the resistance heating layer on the first side of the support between the aerosol generating material and the support, A method wherein at least one of the first type of electrical contact and the second type of electrical contact is accessible from a second side of the support.

16. an aerosol supply system, wherein the aerosol supply system is The device comprises an article and an aerosol supply device configured to receive at least a portion of the article, wherein the article is Aerosol generating materials and A resistance heating layer comprising a resistance heating element configured to heat at least a portion of the aerosol generating material in order to generate an aerosol, The aerosol generating material is located on the resistance heating layer, and the resistance heating layer is located on the resistance heating layer. The first type of electrical contact, A second type of electrical contact, The resistive heating element is at least part of the conductive path between the first type of electrical contact and the second type of electrical contact, A support comprising a support, wherein the resistance heating layer is located on the first side of the support between the aerosol generating material and the support, An aerosol supply system in which at least one of the first type of electrical contact and the second type of electrical contact is accessible from a second side of the support.

17. The aerosol supply system according to claim 16, wherein the aerosol supply device comprises a device electrical connector configured to connect to at least one of the first type of electrical contacts and the second type of electrical contacts.

18. The aerosol supply system according to claim 17, wherein the device electrical connector comprises a puncture element configured to puncture a characteristic portion of the article.

19. The aerosol supply system according to claim 18, wherein the feature portion of the article comprises the support, and the puncture element is configured to puncture the support to make electrical contact with at least one of the first type of electrical contact and the second type of electrical contact.

20. A blank for forming an aerosol generator for an aerosol supply device, wherein the blank is Aerosol generating materials and A resistance heating layer comprising a resistance heating element configured to heat at least a portion of the aerosol generating material in order to generate an aerosol, The first type of electrical contact, A second type of electrical contact, The resistive heating element is at least part of the conductive path between the first type of electrical contact and the second type of electrical contact, A support, wherein the resistance heating layer is located on the first side of the support between the aerosol generating material and the support, A blank comprising an opening in the support such that at least one of the first type of electrical contacts and the second type of electrical contacts is accessible from a second side of the support.

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