aerosol generator

Abstract

An aerosol generator (304) of an article for an aerosol supply device is disclosed. The aerosol generator comprises an aerosol generating material (330) and a resistance heating layer (340) 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 is located on the resistance heating layer. The aerosol generator also comprises a support layer (350) supporting the resistance heating layer and a first type of electrical contact and a second type of electrical contact. The resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact. The support layer is configured to support the first type of electrical contact and the second type of electrical contact.

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, an aerosol supply device comprising an article, and a blank for forming an aerosol generator for an article for an aerosol supply device.

Background Art

[0002] Smoking articles such as cigarettes and cigars burn tobacco during use to produce tobacco smoke. 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, which release compounds by heating a material without burning it. The material may be, for example, tobacco or other non-tobacco products which may or may not contain nicotine.

[0003] Aerosol supply systems covering the above devices or products are known. Common systems use a heater to create an aerosol from a suitable medium, which is then inhaled by the user. Often, the medium used needs to be exchanged 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, comprising 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, wherein the aerosol generating material is located on the resistance heating layer, a support layer configured to support the resistance heating layer, 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, and the support layer is configured to support the first type of electrical contact and the second type of electrical contact.

[0005] In any of the above embodiments, the support layer is electrically insulating.

[0006] In any of the above embodiments, the support layer includes at least one of paper and card.

[0007] In any of the above embodiments, the aerosol generator comprises an aerosol generating layer incorporating an aerosol generating material. In any of the above embodiments, the aerosol generating layer is located on a resistance heating layer.

[0008] In any of the above embodiments, the aerosol generating material is in direct contact with the resistance heating layer.

[0009] In any of the above embodiments, the aerosol generating material is indirectly in contact with the resistance heating layer.

[0010] In any of the above embodiments, the resistance heating layer is sandwiched between the support layer and the aerosol generating material.

[0011] In any of the above embodiments, the resistance heating 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 layer.

[0014] In any of the above embodiments, the area of ​​the support layer corresponds to the area of ​​the resistance heating layer.

[0015] 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 the substrate, or printing the resistance heating layer. Cutting may include die cutting. The resistance heating element may also be formed by an action applied only to the resistance heating layer. In some embodiments, the resistance heating element may be formed by an action applied to both the resistance heating layer and the support layer, for example, an action that cuts the resistance heating layer and the support layer.

[0016] In any of the above embodiments, the resistive heating layer defines at least a portion of the resistive heating element.

[0017] In any of the above embodiments, the resistive heating layer includes a gap that defines at least a portion of the resistive heating element. In any of the above embodiments, the gap defines an electrical insulating barrier. In any of the above embodiments, the gap defines an insulating barrier. In any of the above embodiments, the support layer does not include a gap. In any of the above embodiments, the gap extends through both the support layer and the resistive heating layer. In various embodiments, the gap is a gap filled with, for example, an insulating material.

[0018] In any of the above embodiments, the resistance heating layer, which includes the resistance heating element, is pre-formed and applied to the support layer.

[0019] In any of the above embodiments, the resistive heating layer including the resistive heating element is formed on the support layer.

[0020] In any of the above embodiments, the aerosol generator includes a fold, and the fold defines a first support layer panel and a second support layer panel.

[0021] In any of the above embodiments, the resistive heating layer is on the first support layer panel, and at least one of the first type of electrical contact and the second type of electrical contact is on the second support layer panel.

[0022] In any of the above embodiments, the first support layer panel and the second support layer panel extend parallel to each other.

[0023] In any of the above embodiments, the support layer includes a card layer.

[0024] 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.

[0025] In any of the above embodiments, the support layer defines an exposed contact region of the first type of electrical contact.

[0026] In any of the above embodiments, the exposed contact region is the first exposed contact region, and the support defines a second exposed contact region of the second type of electrical contact.

[0027] In any of the above embodiments, the aerosol generating layer is a continuous aerosol generating layer.

[0028] In any of the above embodiments, the aerosol generating layer is a discontinuous aerosol generating layer.

[0029] In any of the above embodiments, the aerosol generation layer comprises a plurality of individual aerosol generation portions.

[0030] In any of the above embodiments, the resistive heating element is one of a plurality of resistive heating elements.

[0031] 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.

[0032] In any of the above embodiments, the aerosol generation layer comprises at least one of dots, strips, and patches.

[0033] 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-forming material. 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.

[0034] 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.

[0035] 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.

[0036] In any of the above embodiments, the aerosol generation layer comprises a film or gel layer containing an aerosol-forming material.

[0037] In any of the above embodiments, the aerosol generator comprises a plurality of first-type electrical contacts, and each of the heating elements comprises a separate first-type electrical contact.

[0038] 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.

[0039] In any of the above embodiments, the aerosol generator comprises a single second type of electrical contact.

[0040] In any of the embodiments described above, a single second type of electrical contact is shared between each of the resistance heating elements.

[0041] In any of the above embodiments, the resistance heating layer is in the form of a foil.

[0042] According to one embodiment, an aerosol generator for an article for an aerosol supply device is provided, comprising an aerosol generating material and a resistance heating layer comprising a plurality of resistance heating elements, each of the plurality of resistance heating elements configured to heat a respective portion of the aerosol generating material to generate an aerosol, the aerosol generating material being located on the resistance heating layer, a resistance heating layer comprising a first type of electrical contact and a second type of electrical contact, wherein the resistance heating element is at least part of a conductive path between the first type of electrical contact and the second type of electrical contact.

[0043] In any of the above embodiments, the aerosol generator comprises an aerosol generating layer incorporating an aerosol generating material. In any of the above embodiments, the aerosol generating layer is located on a resistance heating layer.

[0044] In any of the above embodiments, the aerosol generator comprises a plurality of first-type electrical contacts, and each of the heating elements comprises a separate first-type electrical contact.

[0045] 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.

[0046] In any of the above embodiments, the aerosol generator comprises a single second type of electrical contact.

[0047] In any of the embodiments described above, a single second type of electrical contact is shared between each of the resistance heating elements.

[0048] In any of the embodiments described above, the electrical contacts allow current to be supplied individually to each of the multiple heating elements.

[0049] According to one embodiment, an aerosol generator for an article for an aerosol supply device is provided, comprising 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, wherein the aerosol generating material is located on the resistance heating layer, the resistance heating layer comprises a first type of electrical contact and a second type of electrical contact, the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact, the aerosol generator comprises a first surface and a second surface different from the first surface, the aerosol generating material is exposed on the first surface, and at least one of the first type of electrical contact and the second type of electrical contact is exposed on the second surface.

[0050] In any of the above embodiments, the aerosol generator comprises an aerosol generating layer incorporating an aerosol generating material. In any of the above embodiments, the aerosol generating layer is located on a resistance heating layer.

[0051] According to one embodiment, an aerosol supply article is provided which comprises an aerosol generating material and one of the aerosol generators described above.

[0052] In any of the embodiments described above, the outer surface of the article has a length, a width perpendicular to the length, and a depth perpendicular to both the length and the width, wherein the length is greater than or equal to the width, and the width is greater than the depth.

[0053] In any of the embodiments described above, the article is tubular.

[0054] In any of the above embodiments, the support layer is tubular.

[0055] In any of the above embodiments, the aerosol generator includes wrap.

[0056] In any of the embodiments described above, the wrap extends around the support layer.

[0057] According to one embodiment, any of the articles described above, which are consumables for an aerosol generation system, are provided.

[0058] According to one embodiment, an aerosol supply system is provided, comprising any of the above-described aerosol generators and an aerosol supply device configured to receive the aerosol generator or an article.

[0059] According to one embodiment, an aerosol supply system is provided comprising any of the above-described aerosol supply devices and an aerosol supply device configured to receive an aerosol generator or article.

[0060] According to one embodiment, an aerosol supply device is provided, configured to receive an article for any of the above-mentioned aerosol generators or aerosol supply devices.

[0061] According to one embodiment, an aerosol supply device is provided that comprises an article of any of the embodiments described above.

[0062] 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 support layer; forming a resistance heating layer comprising a resistance heating element, wherein the resistance heating layer is provided on the support layer; providing an aerosol generating material on the resistance heating layer, wherein the resistance heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol; forming a first type of electrical contact, wherein the first type of electrical contact is provided on the support layer; and forming a second type of electrical contact, wherein the second type of electrical contact is provided on the support layer, wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact.

[0063] In any of the above embodiments, the method includes the step of forming an aerosol-generating layer containing an aerosol-generating material, wherein the aerosol-generating layer is provided on a resistance heating layer.

[0064] 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: forming a resistive heating layer comprising a resistive heating element; providing an aerosol generating material onto the resistive heating layer, wherein the resistive heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol; forming a first type of electrical contact; and forming a second type of electrical contact, wherein the resistive 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.

[0065] According to one embodiment, a blank for forming an aerosol generator of an article for an aerosol supply device is provided, the blank comprising a resistance heating layer, a resistance heating element configured to heat at least a portion of an aerosol generating material received on the resistance heating layer 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.

[0066] In any of the above embodiments, the blank includes an aerosol-generating material.

[0067] In any of the above embodiments, the blank comprises an aerosol-generating layer containing an aerosol-generating material.

[0068] According to one embodiment, an aerosol generator for an article for an aerosol supply device is provided, comprising an aerosol generating material, a resistance heating layer having a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol, a first type of electrical contact, and a second type of electrical contact, wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact.

[0069] In any of the above embodiments, the aerosol generator comprises an aerosol generating layer containing an aerosol generating material.

[0070] In any of the above embodiments, the aerosol-generating material is located on a resistance heating layer.

[0071] According to one embodiment, an aerosol generator is provided, comprising an aerosolizable layer incorporating an aerosolizable material, and a conductive layer in contact with the aerosolizable layer, wherein the conductive layer is formed on a heating element, and the heating element provides a conductive path for resistively heating a portion of the aerosolizable material to generate an aerosol in each portion of the aerosolizable layer, and each heating element comprises a conductive layer extending from a first type of electrical connection to a second type of electrical connection, and a support layer configured to support the first type of electrical connection and the second type of electrical connection.

[0072] According to one embodiment, an aerosol generator for an article for an aerosol supply device is provided, comprising: an aerosol generating material; a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; a support configured to support the resistance heating element; 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, and the resistance heating element is attached to the support by the aerosol generating material.

[0073] In any of the above embodiments, the resistance heating layer includes a resistance heating element.

[0074] In any of the above embodiments, the resistance heating layer comprises a first type of electrical contact and a second type of electrical contact.

[0075] In any of the embodiments described above, the first type of electrical contact and the second type of electrical contact do not overlap with the aerosol-generating material.

[0076] In any of the above embodiments, the aerosol generating layer includes an aerosol generating material.

[0077] In any of the above embodiments, the aerosol generation layer overlaps the resistance heating element.

[0078] In any of the above embodiments, at least a portion of the aerosol-generating layer is bonded to the support.

[0079] In any of the above embodiments, at least a portion of the aerosol-generating layer is adhered to the support.

[0080] In any of the above embodiments, the resistance heating element is sandwiched between the aerosol generation layer and the support.

[0081] In any of the above embodiments, the support comprises a support layer.

[0082] In any of the above embodiments, the resistance heating element is laminated on the support layer by an aerosol generating layer.

[0083] In any of the above embodiments, the resistance heating element is bonded to the support by an aerosol generating material.

[0084] In any of the embodiments described above, the aerosol generation layer covers the support and the resistance heating layer.

[0085] In any of the above embodiments, the aerosol generation layer covers the resistance heating element.

[0086] In any of the above embodiments, the resistance heating element is enclosed by an aerosol generating layer.

[0087] In any of the above embodiments, the resistance heating layer comprises a plurality of individual resistance heating elements, and the plurality of resistance heating elements are bonded to the substrate by an aerosol generating layer.

[0088] In any of the above embodiments, the aerosol generation layer is a single, integrated layer.

[0089] In any of the above embodiments, the aerosol generation layer has a plurality of separate sections.

[0090] In any of the embodiments described above, each of the multiple resistance heating elements is bonded to the substrate by the respective portion of the aerosol generating layer.

[0091] In any of the above embodiments, the aerosol-generating material is a gel.

[0092] In any of the above embodiments, the aerosol-generating layer is a film.

[0093] According to one embodiment, an article for an aerosol supply device is provided, comprising an aerosol generator according to any of the above embodiments.

[0094] According to one embodiment, an aerosol supply system is provided, comprising an aerosol generator or an article for an aerosol supply device according to any of the above embodiments, and an aerosol supply device configured to receive the aerosol generator or the article.

[0095] According to one embodiment, a method is provided for forming an aerosol generator for an article for an aerosol supply device, comprising the steps of: providing a support; forming a resistance heating element, wherein a resistance heating layer is provided on the support; and providing an aerosol generating material, wherein the resistance heating element is attached to the support by the aerosol generating material.

[0096] According to one embodiment, an aerosol generator for an article for an aerosol supply device is provided, comprising an aerosol generating material, a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol, a support configured to support the resistance heating element, 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, and the resistance heating layer includes a barrier coating.

[0097] In various embodiments, the coating may be a layer, a cover, a lubricant, or a film.

[0098] In any of the embodiments described above, the barrier coating is lacquer.

[0099] In any of the embodiments described above, the barrier coating is configured to prevent corrosion.

[0100] In any of the above embodiments, at least a portion of the barrier coating is provided between the resistance heating layer and the aerosol generation layer.

[0101] Next, various embodiments will be described as mere examples, with reference to the attached schematic drawings. [Brief explanation of the drawing]

[0102] [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 diagram showing the aerosol generator that has been formed. [Figure 24] Another diagram showing the aerosol generator that is being formed. [Figure 25] Another diagram showing the aerosol generator that is being formed. [Figure 26] This is a schematic perspective view of the aerosol generator that has been formed. [Figure 27]Figure 26 is a schematic perspective view of the aerosol generator in its formed state. [Figure 28] This diagram shows a method for forming an aerosol generator. [Modes for carrying out the invention]

[0103] 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.

[0104] 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.

[0105] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] In some embodiments, the delivered substance includes an active substance (sometimes referred to herein as an active compound).

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] The slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0125] 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.

[0126] 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.

[0127] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0128] 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.

[0129] 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.

[0130] 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.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] The aerosol supply system 100 is elongated and may extend 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.

[0136] 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.

[0137] 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. As shown in Figure 5, an article receiving portion 206, sometimes called a device chamber, is configured to receive a portion of article 300. The proximal end 308 of the article protrudes from the device 200 when article 300 is received into the device chamber 206. A receptacle 208 defines the chamber 206. The receptacle 208 comprises a receptacle base 210 and a receptacle periphery 212. The configuration of the receptacle 208 may vary depending on the configuration of article 300.

[0138] 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.

[0139] 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 other embodiments, the device 200 defines a mouthpiece. The user places their mouth over the mouthpiece during use.

[0140] Device 200 defines a longitudinal axis along which article 300 may extend when inserted into device 200. The opening 214 is aligned on the longitudinal axis. The longitudinal axis may also be the axis along which article 300 is inserted into device 200. The longitudinal axis may be considered the receiving axis of device 200. Article 300 may also have a longitudinal axis along which it is inserted into the device, and this axis may be considered the insertion axis.

[0141] 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 that functions as a controller, which includes a processor and memory.

[0142] 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.

[0143] 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.

[0144] The heating element 312 is a resistance heating element. The heating element or each heating element in the embodiments is a resistance heating element, as will be described in detail below. In such an arrangement, the heating system 110 comprises a resistance heating generator which includes components for heating the heating element 312 by a resistance heating process. In this case, a current is applied directly to the resistance heating element, and the heating element is heated by Joule heating due to the resulting current flow within the heating element which acts as a heating element. The resistance heating element includes a resistance material configured to generate heat when a suitable current passes through the resistance material, and the heating element 312 comprises electrical contacts for supplying current to the resistance material. The provision of the resistance heating element 312 enables a compact configuration. Resistance heating provides an efficient configuration.

[0145] 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 device at the aerosol outlet 318, as indicated by arrow 319. In some embodiments, the aerosol outlet 318 is located in the mouthpiece of the article 300 so that the aerosol is drawn directly from the article 300 to the user's mouth of the system 100.

[0146] 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.

[0147] 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.

[0148] 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 contact 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.

[0149] The configuration of article 300 may vary. As described herein, the article is a flat article or consumable. The outer surface of article 300 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. In some embodiments, the article is tubular; that is, article 300 has a tubular configuration. In such an arrangement, the aerosol generator may have a tubular configuration.

[0150] 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 through which air and / or aerosols can flow within the article. 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 various embodiments, the internal space comprises one chamber, or the internal space comprises two or more chambers.

[0151] 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 feature. 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.

[0152] 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.

[0153] 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, an elliptical cross-section, and other polygonal shapes.

[0154] 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.

[0155] 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.

[0156] The wrap surrounds the article 300 and forms part of the article 300. The wrap may include a sheet. The wrap functions as a fixing sleeve. The aerosol generator or each aerosol generator 304 protrudes from the wrap at its distal end. The exposed electrical contact area 323 of the heater contact 322 is exposed at its distal end; see, for example, Figure 2. 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.

[0157] 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.

[0158] 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 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] Article 300 may comprise 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.

[0163] 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.

[0164] 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.

[0165] Figure 8 shows one of the resistance heating elements 342. The resistance heating layer 340 comprises a plurality of resistance heating elements 342. In some embodiments, the resistance heating layer 340 comprises a single resistance heating element 342.

[0166] Multiple heating elements 342 may be formed in an array 344 as shown in Figure 9. Other configurations are also possible.

[0167] 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, as well as the material.

[0168] The resistive heating element 342 extends between the first type of electrical contact 360 and the 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 type of electrical contacts 360, 365 constitute the heater electrical contact 322. The first and second type of electrical contacts 360, 365 form at least a portion of the article electrical contact configuration 320.

[0169] 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.

[0170] The resistance heating layer 340 may include a first type of electrical track 361 extending from the resistance heating element 342. The first type of electrical track 361 includes a first type of electrical contact 360. The first type of electrical contact 360 is configured to electrically connect to the device electrical connector 230. The first type of electrical contact 360 includes a first type of exposed contact area 362. The first type of exposed contact area 362 is exposed on the article for direct connection to the device electrical connector 230.

[0171] The resistance heating layer 340 may include a second type of electrical track 366 extending from the resistance heating element 342. The second type of electrical track 366 includes a second type of electrical contact 365. The second type of electrical contact 365 is configured to electrically connect to the device electrical connector 230. The second type of electrical contact 365 includes a second type of exposed contact area 367. The second type of exposed contact area 367 is exposed on the article 300 for direct connection to the device electrical connector 230.

[0172] 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.

[0173] 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.

[0174] At least one electrical insulating barrier 346 defines first and second types of electrical tracks 361, 366.

[0175] 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.

[0176] As shown in Figure 9, the resistive heating layer 340 may be formed in 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.

[0177] 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.

[0178] 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.

[0179] In the exemplary resistance heating layer 340, a plurality of first type electrical contacts 360a to 360e, for example, positive electrical connections, and a single second type electrical contact 365, for example, a negative electrical connection, are provided. This is not essential for all implementation configurations. For example, multiple second type contacts could be provided. In various embodiments, each resistance 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.

[0180] 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.

[0181] 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.

[0182] 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 the 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 different configurations. In various embodiments, the aerosol-generating material is mounted on the support with respect to the resistive heating layer, as described below with reference to, for example, Figures 26-28.

[0183] In operation 404, the formed resistance heating layer is positioned to be in contact with the aerosol generating layer, which incorporates the aerosol generating material. The aerosol generator 304 described above can be produced using algorithm 400.

[0184] 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.

[0185] 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.

[0186] Figure 13 is a flowchart illustrating 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. Then, in operation 416, an aerosol generating material is disposed on the resistive heating layer. Thus, operation 416 is an exemplary implementation of operation 404 described above.

[0187] 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 in operation 420, where one or more heating elements are formed at least partially by printing a resistance heating layer. Thus, operation 420 is an exemplary implementation of operation 402 of algorithm 400 described above. Next, in operation 422, the aerosol generating material is placed on the resistance heating layer. Thus, operation 422 is an exemplary implementation of operation 404 described above.

[0188] 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.

[0189] 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.

[0190] 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.

[0191] 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.

[0192] 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.

[0193] 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.

[0194] 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.

[0195] 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.

[0196] 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.

[0197] The resistive heating element 342 is located inside the resistive heating layer 340. The inside defines the first side 306 of the aerosol generator 304, as shown in Figure 3. The heater contact 322 is located on the second side 307 of the resistive heating layer 340. The second side 307 defines the outside of the aerosol generator 304. The heater contact 322 is exposed so that it can make contact with the device electrical connector 230. The heater contact 322 is located on the opposite side of the resistive heating layer 340 from the resistive heating element 342. Other configurations are possible.

[0198] The support layer 350 is located between the inner portion and the outer portion of the resistance heating layer 340.

[0199] A fold 370 is formed in the resistance heating layer 340. The fold 370 defines the heater contact 322. The fold 370 shown in Figures 2-4 and Figure 19 extends perpendicular to the longitudinal axis of the aerosol generator 304. The fold 370 defines the flap 372. The heater contact 322 is located on the flap 372. The flap defines the contact panel. The remaining blank defines the main panel. The fold 370 is formed by a fold line. The fold lines in various embodiments are predetermined. The fold lines extend perpendicular to the longitudinal direction, but other arrangements are also possible. The fold lines are linear.

[0200] In embodiments having a support layer 350, the support layer 350 is folded in various embodiments. The base material 352 is folded at a fold 370. In various embodiments, the support layer 350 terminates at the fold. In various embodiments, the fold 370 extends parallel to the longitudinal axis of the aerosol generator 304. The aerosol generator includes the fold. In various embodiments, the fold defines a first support layer panel and a second support layer panel. In such embodiments, the resistance heating layer may be provided on the first support layer panel, and at least one or each of the first type of electrical contacts and the second type of electrical contacts are provided on the second support layer panel.

[0201] When the base material 352 is bent, the first support layer panel and the second support layer panel extend parallel to each other. In various embodiments, the first support layer panel and the second support layer panel are fixed to each other to maintain the bent state.

[0202] The bent portion of the resistance heating layer 340 is fixed in the bent position. In various embodiments, this bent portion is bonded, for example, by a joint. Other fixing means are anticipated.

[0203] The fold 370 defines a first type of exposed contact area 362. The fold 370 defines a second type of exposed contact area 367. Electrical tracks 361 and 366 are electrically connected across the fold 370. Heater contacts 322 of the first type of electric track 361 and the second type of electric track 366 are defined on the second side of the resistive heating layer 340. Parts of the first type of electric track 361 and the second type of electric track 366 extend along the first side of the resistive heating layer 340. In some embodiments, the resistive heating element extends from the fold 370. Other configurations are anticipated.

[0204] 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 heater contacts 322, including multiple first-type heater contacts 360 and one of second-type heater contacts 365. Article 300 includes another set of heater contacts 322 on the opposite side of article 300, corresponding to the second aerosol generator 304.

[0205] 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.

[0206] 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.

[0207] 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.

[0208] 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.

[0209] 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.

[0210] In operation 442, the aerosol-generating material is applied and / or formed on the resistance heating layer.

[0211] 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.

[0212] 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.

[0213] In some embodiments, the first and second types of electrical contacts are formed along or near a single edge of the resistance heating layer. In some embodiments, the first and second types of electrical contacts are formed along or near different edges of the resistance heating layer.

[0214] In some embodiments, a first type of electrical contact (e.g., a positive connection) is provided along a first edge of the resistance heating layer. In some embodiments, a second type of electrical contact (e.g., a negative electrical connection) is provided along a second edge of the resistance heating layer. Operations 446 and 448 can be performed in different orders or simultaneously. Furthermore, operations 446 and 448 can be performed together with operation 442.

[0215] In operation 450, the resistance heating layer is bent. In some embodiments, the support layer is bent together with the resistance heating layer. In some embodiments, the resistance heating layer is bent so that the first and second types of electrical contacts are adjacent to each other, as will be discussed in detail below.

[0216] Figures 23 to 25 show embodiments of the aerosol generator 304 formed according to algorithm 440.

[0217] Figure 23 shows another embodiment of the formed aerosol generator 304. The resistance heating layer 340 is cut using a laser cutter 408. The pre-folded configuration defines a blank for forming the aerosol generator 304. In the embodiments, the blank defines fold lines along which folds are made during the formation of the aerosol generator. The blank of the aerosol generator 304 comprises a resistance heating layer 340 and a support layer 350. The resistance heating layer 340 and the support layer 350 define a panel defined by the fold lines.

[0218] As shown in Figure 23, the resistance heating layer 340 is formed on multiple heating elements 192, but the number may vary, or there may be only one. Multiple first type electrical contacts 360 (e.g., positive electrical contacts) are provided along the first edge of the conductive layer (one contact is shown for each heating element). A single second type electrical contact 365 is provided along the second edge of the resistance heating layer 340. In various embodiments, the contacts are spaced apart from the edge. As discussed above, each of the multiple heating elements extends from the first type electrical contact to the second type electrical contact.

[0219] Cutting the resistance heating layer 340 with 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 and printing.

[0220] As shown in Figure 24, the aerosol generating layer 200 is provided on the resistance heating layer 340. Next, the blank is folded as indicated by the arrows in Figure 24. In this embodiment, the folds are formed parallel to the longitudinal direction of the aerosol generator 304. Two folds are formed. A first panel 375, comprising a heating element 342, is defined. A second panel 376, comprising a plurality of first-type electrical contacts 360, is formed. A third panel 377, comprising second-type electrical contacts 365, is formed. The aerosol generating layer 330 is on the first panel 375. Figure 25 shows the folded aerosol generator 304. The second and third panels 376 and 377 are coplanar. The first-type electrical contacts 360 and the second-type electrical contacts are defined on the opposite side of the formed, i.e., folded, resistance heating layer 340 from the heating element 342.

[0221] Figures 26 and 27 show another embodiment of the aerosol generator 504. The article for the aerosol supply device 200 comprises the aerosol generator 504. The aerosol generator 504 is substantially the same as the aerosol generator shown and described in relation to Figures 1 to 25.

[0222] Individual resistance heating elements 542 are provided on a support 550. Each resistance heating element is formed separately. Figure 26 shows the first resistance heating element 542a, the second resistance heating element 542b, the third resistance heating element 542c, the fourth resistance heating element 542d, and the fifth resistance heating element 542e. The number of resistance heating elements may vary. Multiple resistance heating elements 542 are attached to the support 550. Multiple resistance heating elements 542 are attached to the support 550 by an aerosol generating material 502. In some embodiments, the resistance heating elements are not individual to one another. The resistance heating elements 542 define the resistance heating layer. Multiple resistance heating elements 542 are attached to the support 550 by an aerosol generating material.

[0223] The aerosol generating material 502 overlaps with a plurality of resistance heating elements 542. The aerosol generating layer 530 incorporates the aerosol generating material 502. The aerosol generating layer 530 is a single, integrated layer. In some embodiments, individual portions of the aerosol generating material 502 are provided. These individual portions of the aerosol generating material 502 may be aligned with corresponding individual resistance heating elements 542. A single layer of the aerosol generating material 502 covers a plurality of resistance heating elements 542. The resistance heating layer 540 incorporates a plurality of resistance heating elements 542. The aerosol generating material 502 covers the resistance heating layer 540. The plurality of resistance heating elements 542 in the resistance heating layer 540 are electrically connected. The resistance heating layer 540 includes a first type of electrical contact and a second type of electrical contact, which are omitted from the figure and correspond to those described above.

[0224] In various embodiments, any number of resistance heating elements, including one element, may be used. The resistance heating layer 540 may comprise a plurality of individual resistance heating elements 542. Each resistance heating element may comprise a first type of electrical contact and a second type of electrical contact. The plurality of resistance heating elements 542 may be bonded to the support 550 by an aerosol generating material 502. In various embodiments, each resistance heating element may be attached to the support 550 by a separate section of the aerosol generating material. Each of the plurality of resistance heating elements 542 is bonded to the support by its respective section of the aerosol generating material 502. In various embodiments, the first type of electrical contact and the second type of electrical contact do not overlap with the aerosol generating material. The first type of electrical contact and the second type of electrical contact are exposed to contact the device connector as described above.

[0225] In various embodiments, the aerosol generating material 502 is formed in the aerosol generating layer 530. The aerosol generating layer 530 overlaps with a plurality of resistance heating elements 542. The aerosol generating material 502 covers the plurality of resistance heating elements 542. The plurality of resistance heating elements 542 are encompassed by the aerosol generating layer 530. The aerosol generating material 502 extends across the plurality of resistance heating elements 542. At least a portion of the aerosol generating layer 530 is in contact with the support 550. At least a portion of the aerosol generating layer 530 is bonded to the support 550. At least a portion of the aerosol generating layer 530 is adhered to the support 550. The plurality of resistance heating elements 542 are sandwiched between the aerosol generating layer 530 and the support 550. In the illustrated embodiment, at least a portion of the support is not covered by the aerosol generating material. A portion of the support is exposed. In other embodiments, the aerosol generating material may cover the support to a different degree. In various embodiments, the aerosol generating material 502 may be a solid, a gel, or a film.

[0226] The support 550 comprises a support layer, which is a base layer. The resistance heating element or each resistance heating element 542 is laminated to the support layer 550 by an aerosol generating layer 530. Multiple resistance heating elements 542 are bonded to the support 550 by an aerosol generating material 502. The aerosol generating layer 530 covers the support 550 and the resistance heating layer 540. The support 550 may include card, paper, or another suitable material.

[0227] As in other embodiments, the aerosol supply system 100 may include an aerosol generator 504, or an article comprising an aerosol generator 504 for the aerosol supply device 200, and an aerosol supply device 200 configured to receive the aerosol generator 504 or the article.

[0228] The aerosol generator 504 may be formed by a manufacturing method 600 shown in Figure 28. The method is a process for manufacturing or forming an aerosol generator 504 of an article that can be used in an aerosol supply device 200. The method includes a method step 601 of providing a support and a method step 602 of forming a resistance heating element. The resistance heating element is formed as part of a resistance heating layer. The resistance heating element is provided on the support. The method further includes a step 603 of providing an aerosol generating material. The resistance heating element is attached to the support by the aerosol generating material 604. In some embodiments, the aerosol generating material may be a layer, a cover or a film. The resistance heating element is attached to the support by the aerosol generating material in the same manner as described in relation to Figures 26 and 27.

[0229] In embodiments such as those described above or alternative embodiments, the aerosol generator includes a coating 570. The resistive heating element or each resistive heating element 542 includes a coating 570. The resistive heating layer 540 includes a coating 570. The coating 570 is a barrier coating. At least a portion of the barrier coating 570 is provided between the resistive heating layer 540 and the aerosol generating layer 530. The barrier coating 570 provides a cover that separates the resistive heating elements 542 from the aerosol generating material 502. The coating 570 is configured to protect the resistive heating element or each resistive heating element 542. The coating 570 forms a barrier to protect the resistive heating element or each resistive heating element 542 from corrosion or oxidation. In some embodiments, the coating 570 may be a layer, a cover, a lubricant, or a film. In some embodiments, the barrier coating is lacquer.

[0230] 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 material 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.

[0231] 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.

[0232] 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.

[0233] 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.

[0234] 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.

[0235] 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.

[0236] 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.

[0237] As described herein, the article forms part of the system together with the aerosol supply device. In various embodiments, the aerosol supply device comprises the article.

[0238] 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. A support layer configured to support the aforementioned resistance heating layer, The first type of electrical contact, It is equipped with a second type of electrical contact, The resistive heating element is at least a part of the conductive path between the first type of electrical contact and the second type of electrical contact. An aerosol generator in which the support layer is configured to support the first type of electrical contact and the second type of electrical contact.

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

3. The aerosol generator according to claim 1 or 2, wherein the support layer includes at least one of paper and card.

4. The aerosol generator according to any one of claims 1 to 3, comprising an aerosol generating layer containing the 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 the aerosol generating material is in direct contact with the resistance heating layer.

6. The aerosol generator according to any one of claims 1 to 5, wherein the aerosol generating material is indirectly in contact with the resistance heating layer.

7. The aerosol generator according to any one of claims 1 to 6, wherein the resistance heating layer is sandwiched between the support layer and the aerosol generating material.

8. The aerosol generator according to any one of claims 1 to 7, wherein the aerosol generator comprises a laminate having the resistance heating layer and the support layer.

9. The aerosol generator according to any one of claims 1 to 8, wherein the area of ​​the support layer corresponds to the area of ​​the resistance heating layer.

10. The aerosol generator according to any one of claims 1 to 9, wherein the resistive heating layer includes a gap defining at least a portion of the resistive heating element, and the support layer does not include the gap.

11. An aerosol generator according to any one of claims 1 to 10, comprising a fold, wherein the fold defines a first support layer panel and a second support layer panel.

12. An aerosol generator for an aerosol supply device, wherein the aerosol generator is Aerosol generating materials and A resistance heating layer comprising a plurality of resistance heating elements, wherein each of the plurality of resistance heating elements is configured to heat a respective 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, It is equipped with a second type of electrical contact, An aerosol generator in which the resistive heating element is at least part of a conductive path between the first type of electrical contact and the second type of electrical contact.

13. An aerosol generator for an aerosol supply device, 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, wherein the aerosol generating material is located on the resistance heating layer, The first type of electrical contact, It is equipped with a second type of electrical contact, The resistive heating element is at least a part of the conductive path between the first type of electrical contact and the second type of electrical contact. The aerosol generator comprises a first surface and a second surface different from the first surface, The aerosol generating material is exposed on the first surface, An aerosol generator in which at least one of the first type of electrical contact and the second type of electrical contact is exposed on the second surface.

14. An article for an aerosol supply device comprising an aerosol generating material and an aerosol generator according to any one of claims 1 to 13.

15. The article according to claim 14, wherein 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 the width, wherein the length is greater than or equal to the width and the width is greater than the depth.

16. The article according to claim 14, wherein the article is tubular.

17. An aerosol supply system comprising an article for an aerosol generator according to any one of claims 1 to 13, or for an aerosol supply device according to any one of claims 14 to 16, and an aerosol supply device configured to receive the aerosol generator or the article.

18. A method for forming an aerosol generator for an aerosol supply device, wherein the method is Steps include providing a support layer, A step of forming a resistance heating layer comprising a resistance heating element, wherein the resistance heating layer is provided on the support layer, A step of providing an aerosol generating material on the resistance heating layer, wherein the resistance heating element is configured to heat at least a portion of the aerosol generating material in order to generate an aerosol; A step of forming a first type of electrical contact, wherein the first type of electrical contact is provided on the support layer, The process includes the step of forming a second type of electrical contact, wherein the second type of electrical contact is provided on the support layer, A method wherein the resistive heating element is at least part of a conductive path between the first type of electrical contact and the second type of electrical contact.

19. A blank for forming an aerosol generator for an aerosol supply device, wherein the blank is A resistance heating layer comprising a resistance heating element configured to heat at least a portion of an aerosol generating material received on the resistance heating layer 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 blank comprising the resistance heating layer, a support layer configured to support the first type of electrical contact and the second type of electrical contact.

20. An aerosol generator for an aerosol supply device, wherein the aerosol generator is Aerosol generating materials and A resistance heating element configured to heat at least a portion of the aerosol generating material in order to generate an aerosol, A support configured to support the aforementioned resistance heating element, The first type of electrical contact, It is equipped with a second type of electrical contact, The resistive heating element is at least a part of the conductive path between the first type of electrical contact and the second type of electrical contact. An aerosol generator in which the resistance heating element is attached to the support by the aerosol generating material.

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