Aerosol supply system

Abstract

An aerosol supply system comprising: an aerosol supply device having an article receiving portion; and an aerosol-forming article having an oral end and a distal end such that its longitudinal axis extends between the distal end and the oral end, wherein the aerosol-forming article is configured to be inserted laterally into the article receiving portion, and its lateral direction is perpendicular to the longitudinal axis.

Description

Technical Field

[0001] [Priority Claim] This application claims priority from UK Patent Application No. 2317729.8, entitled "Aerosol Supply System", filed on November 20, 2023, UK Patent Application No. 2304638.6, entitled "Aerosol Supply System", filed on March 29, 2023, and US Patent Application No. 18 / 367274, entitled "Aerosol Supply System", filed on September 12, 2023, all of which are hereby incorporated by reference in their entirety.

[0002] The present invention relates to an aerosol supply system and an aerosol forming article.

Background Art

[0003] Smoking articles such as cigarettes and cigars generate tobacco smoke by burning tobacco during use. Attempts have been made to provide alternatives to these articles by creating products that release compounds without burning. Examples of such products include so-called "non-combustion heating" products that release compounds by heating a material without burning, or tobacco heating devices or products. The material may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine.

[0004] Aerosol supply systems covering the above-mentioned devices or products are known. A common system uses a heater to generate an aerosol from a suitable medium, which is then inhaled by the user. In many cases, in order to supply different aerosols for inhalation, it is necessary to exchange or change the medium used. It is known to use a resistive heating system as a heater for generating an aerosol from a suitable medium.

Summary of the Invention

[0005] According to one embodiment, an aerosol supply system is provided, comprising: an aerosol supply device having an article receiving portion; and an aerosol-forming article having an oral end and a distal end such that the longitudinal axis extends between the distal end and the oral end, wherein the aerosol-forming article is configured to be inserted laterally into the article receiving portion, and the lateral direction is perpendicular to the longitudinal axis.

[0006] A portion of the aerosol-forming article may be visible when the aerosol-forming article is inserted into the article receiving portion.

[0007] The aerosol receiving portion may include a notch that exposes a portion of the aerosol-forming article.

[0008] The aerosol-forming article may have an article inlet located on its lateral side, and the lateral side is offset laterally from the longitudinal axis.

[0009] The aerosol-forming article may include electrical contacts formed on a first surface of the aerosol-forming article toward its lateral side.

[0010] The electrical contacts may include a first type of electrical contact and a second type of electrical contact.

[0011] The aerosol-forming article may include an aerosol generator, the aerosol generator comprising an aerosol-generating material and a resistance heating layer comprising a plurality of resistance heating elements, wherein the aerosol-generating material is located on the resistance heating layer, and each resistance heating element is configured to heat at least a portion of the aerosol-generating material to generate an aerosol.

[0012] The resistance heating element and electrical contacts may be positioned on the first surface of the resistance heating layer.

[0013] The aerosol generator may include an aerosol generating layer containing an aerosol generating material. The aerosol generating layer may be located on a resistance heating layer.

[0014] The resistance heating layer may extend beyond the aerosol generating material so that electrical contacts are exposed.

[0015] The aerosol supply device may include a wrapping layer that covers the aerosol generating material. The resistance heating layer may extend beyond the wrapping layer so that electrical contacts are exposed.

[0016] The aerosol supply device may include an inlet channel and a compression seal, the compression seal being configured to seal the inlet channel to the article inlet.

[0017] The aerosol supply device may include a puff sensor that communicates with the inlet channel and the fluid.

[0018] The compression seal may be positioned on the first side of the article receiving portion.

[0019] The compression seal may be positioned adjacent to the lateral surface of the aerosol-forming article.

[0020] The aerosol-forming article may include an extension portion that extends laterally from the aerosol-forming article, and the extension portion is received by the article receiving portion.

[0021] According to one embodiment, an aerosol-forming article is provided, comprising an oral end and a distal end, the longitudinal axis of which extends between the distal end and the oral end, wherein the aerosol-forming article is configured to be inserted laterally into an aerosol supply device, and the later direction is perpendicular to the longitudinal axis.

[0022] According to one embodiment, an aerosol supply system is provided, comprising an aerosol supply device having an inlet channel and a compression seal, and an aerosol-forming article having an article inlet, wherein the compression seal is configured to seal the inlet channel to the article inlet.

[0023] The compression seal may be formed of a foam.

[0024] The compression seal may be formed of silicone.

[0025] The aerosol-forming article may comprise a mouth end and a distal end with a longitudinal axis extending between the distal end and the mouth end, and the article inlet may be positioned on a lateral side of the aerosol-forming article, the lateral side being offset from the longitudinal axis.

[0026] The aerosol supply device may comprise a puff sensor in fluid communication with an inlet flow path.

[0027] The compression seal may be positioned parallel to a lateral side of the aerosol-forming article.

[0028] The compression seal may be positioned on a first side of the article receiving portion.

[0029] The aerosol-forming article may be configured to be inserted laterally into the article receiving portion, the lateral direction being perpendicular to the longitudinal axis.

[0030] According to one aspect, there is provided an aerosol supply device comprising an inlet flow path and a compression seal and configured to receive an aerosol-forming article having an article inlet, the compression seal being configured to seal the inlet flow path to the article inlet.

[0031] According to one aspect, there is provided an aerosol supply system comprising an aerosol supply device comprising an inlet flow path and a compression seal, and an aerosol-forming article comprising an article inlet, the compression seal being configured to seal the inlet flow path to the article inlet.

[0032] The aerosol-forming article may comprise a mouth end and a distal end with a longitudinal axis extending between the distal end and the mouth end, and the article inlet may be positioned at the distal end of the article.

[0033] The aerosol-forming article may be configured to be inserted into the article receiving portion in a direction parallel to the longitudinal axis.

[0034] The compression seal may include a contact surface positioned to contact the article and seal the inlet passage to the article inlet, and the contact surface may be substantially flat.

[0035] The compression seal may include a contact surface positioned to contact the article and seal the inlet passage to the article inlet, and the contact surface may be rounded.

[0036] The compression seal may include a wall, one end of which defines a contact surface positioned to contact the article and seal an inlet passage to the article inlet, and the wall may further define a sealing air passage.

[0037] The wall may be substantially straight such that the sealing air passage has a substantially constant cross-sectional area.

[0038] At least a portion of the wall may extend outward in a direction from the base of the wall toward the contact surface such that at least a portion of the sealing air passage increases the cross-sectional area between the base and the contact surface.

[0039] The wall thickness may vary along the length of the wall from the base to the contact surface.

[0040] The wall thickness may decrease along at least a portion of the wall length in the direction from the base to the contact surface.

[0041] The article receiving portion may include a stopper portion positioned to limit the amount of compression that the article can apply to the compression seal.

[0042] The stopper portion may include at least one projection extending into the article receiving portion.

[0043] At least one projection may be positioned adjacent to the compression seal.

[0044] The aerosol supply device may further include a puff sensor that communicates with the inlet channel and the fluid.

[0045] According to one embodiment, an aerosol-forming article for an aerosol supply device is provided, extending along a longitudinal axis from a mouth end to a distal end, the aerosol-forming article comprising an aerosol generator, the aerosol generator comprising an aerosol-forming material and a resistance heating layer comprising a plurality of resistance heating elements, wherein the aerosol-forming material is located on the resistance heating layer and each resistance heating element is configured to heat at least a portion of the aerosol-forming material to generate an aerosol, the resistance heating layer comprising an electrical track extending from the resistance heating elements, the electrical track comprising electrical contacts configured to electrically connect the resistance heating elements to device contacts, the resistance heating elements and electrical contacts are positioned on a first surface of the resistance heating layer, and the resistance heating layer extends beyond the aerosol-forming material so that the electrical contacts are exposed.

[0046] The aerosol generator may include an aerosol generating layer containing an aerosol generating material. The aerosol generating layer may be located on a resistance heating layer. The resistance heating layer may extend beyond the aerosol generating material so that electrical contacts are exposed.

[0047] The resistance heating layer may extend laterally beyond the aerosol generating material so that the resistance heating layer is exposed.

[0048] The aerosol-forming article may have multiple electrical contacts.

[0049] The electrical contacts may include a first type of electrical contact and a second type of electrical contact.

[0050] The first type of electrical contact may be positioned along the first edge of the resistance heating layer.

[0051] The second type of electrical contact may be positioned along the second edge of the resistance heating layer.

[0052] The resistive heating element may extend from a first type of electrical contact to a second type of electrical contact.

[0053] Each of the resistive heating elements may have a separate electrical contact of the first type.

[0054] The aerosol-forming article may further comprise a support layer.

[0055] The support layer may be made of cardboard.

[0056] The aerosol-forming article may further comprise a wrapping layer.

[0057] The resistance heating layer may extend beyond the support layer and the wrapping layer so that the electrical contacts are exposed.

[0058] According to one embodiment, an aerosol supply system is provided, comprising an aerosol supply device and an aerosol-forming article for the aerosol supply device extending along a longitudinal axis from the mouth end to the distal end, wherein the aerosol-forming article comprises an aerosol generator, the aerosol generator comprising an aerosol-forming material and a resistance heating layer comprising a first and second resistance heating element, wherein the aerosol-forming material is located on the resistance heating layer and each of the first and second resistance heating elements is configured to heat at least a portion of the aerosol-forming material to generate an aerosol, the resistance heating layer comprising an electrical track extending from the resistance heating element, the electrical track comprising an electrical contact configured to electrically connect the resistance heating element to a device contact, the resistance heating element and the electrical contact are positioned on a first surface of the resistance heating layer, and the resistance heating layer extends beyond the aerosol-forming material so that the electrical contact is exposed.

[0059] The aerosol generator may include an aerosol generating layer containing an aerosol generating material. The aerosol generating layer may be located on a resistance heating layer. The resistance heating layer may extend beyond the aerosol generating material so that electrical contacts are exposed.

[0060] According to one embodiment, an aerosol supply device is provided, comprising: a receptacle having an opening for receiving at least a portion of an aerosol-forming article containing an aerosol-generating material into the aerosol supply device; and a suction port having a defined proximal end, from which a user can aspirate an aerosol generated from the aerosol-generating material, wherein the opening is defined at the distal end of the aerosol supply device relative to the proximal end of the aerosol supply device, and the aerosol supply device comprises an electrical connector, the electrical connector having a plurality of electrical contacts configured to contact the aerosol-forming article in the receptacle.

[0061] A portion of the aerosol-forming article may be visible when the aerosol-forming article is inserted into the receptacle.

[0062] The receptacle may have a notch that exposes a portion of the aerosol-forming article.

[0063] According to one embodiment, an aerosol supply system is provided that comprises the above-described aerosol supply device and an aerosol-forming article.

[0064] The aerosol-forming article may include an aerosol generator, the aerosol generator comprising an aerosol-generating material and a resistance heating layer comprising a plurality of resistance heating elements, wherein the aerosol-generating material is located on the resistance heating layer, and each resistance heating element is configured to heat at least a portion of the aerosol-generating material to generate an aerosol.

[0065] The aerosol generator may include an aerosol generating layer containing an aerosol generating material. The aerosol generating layer may be located on a resistance heating layer.

[0066] The aerosol-forming article may have an article inlet and an article outlet, and the aerosol supply device may have a device inlet, a device outlet and a device flow path, the device flow path connecting the device inlet and the device outlet so that the device inlet and the device outlet are in fluid communication, and the suction port is provided with the device outlet.

[0067] The device inlet may be in fluid communication with the article outlet.

[0068] The device may further include a pressure sensor that communicates with the device's fluid pathway.

[0069] The resistive heating element may be arranged in a U-shape on the first side surface of the resistive heating layer.

[0070] The aerosol-forming article may include electrical contacts formed on a first surface of the aerosol-forming article toward the proximal end of the aerosol-forming article.

[0071] The electrical contacts may include a first type of electrical contact and a second type of electrical contact.

[0072] In any of the embodiments described above, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to 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.

[0073] In any of the above embodiments, the aerosol generator includes a support configured to support a resistance heating layer.

[0074] In any of the above embodiments, the support comprises a support layer.

[0075] In any of the above embodiments, the support is electrically insulating.

[0076] In any of the above embodiments, the support comprises at least one of paper and card.

[0077] In any of the above embodiments, the aerosol generating material is in direct contact with the resistance heating layer.

[0078] In any of the above embodiments, the aerosol generating material is indirectly in contact with the resistance heating layer.

[0079] In any of the embodiments described above, the resistance heating layer and the support layer define the substrate.

[0080] In any of the above embodiments, the aerosol generator comprises a laminate having a resistance heating layer and a support layer.

[0081] In any of the above embodiments, the laminate includes an aerosol-generating layer.

[0082] In any of the above embodiments, the support layer comprises a card layer.

[0083] In any of the embodiments described above, the first type of electrical contact is configured to be electrically connected to the device electrical connector, and the second type of electrical contact is configured to be electrically connected to the device electrical connector.

[0084] In any of the embodiments described above, the support defines the exposed contact area of ​​the first type of electrical contact.

[0085] In any of the embodiments described above, the exposed contact area is a first exposed contact area, and the support defines a second exposed contact area of ​​a second type of electrical contact.

[0086] In any of the above embodiments, the aerosol generation layer is a continuous aerosol generation layer.

[0087] In any of the above embodiments, the aerosol generation layer is a discontinuous aerosol generation layer.

[0088] In any of the above embodiments, the aerosol generation layer comprises a plurality of individual aerosol generation portions.

[0089] In any of the above embodiments, the resistive heating element is one of a plurality of resistive heating elements.

[0090] In any of the embodiments described above, one of the individual aerosol generating units is associated with a corresponding one of a plurality of resistance heating elements.

[0091] In any of the embodiments described above, the aerosol-generating layer includes at least one of dots, strips, and patches.

[0092] In any of the above embodiments, the resistance heating element is a first heating element, the resistance heating layer forms a second resistance heating element, and each resistance heating element provides a conductive path for resistively heating a portion of the aerosol generating material, thereby generating an aerosol in each portion of the aerosol generating material.

[0093] In any of the above embodiments, the resistance heating layer forms an array of resistance heating elements comprising at least a first resistance heating element and a second resistance heating element.

[0094] In any of the embodiments described above, each of the first type of electrical contact and each of the second type of electrical contact is configured to supply current to each of the resistance heating elements individually.

[0095] In any of the above embodiments, the aerosol generating layer comprises a film or gel layer containing an aerosol generating material.

[0096] 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.

[0097] In any of the embodiments described above, the aerosol generator comprises a plurality of second types of electrical contacts, and each of the resistance heating elements comprises a separate second type of electrical contact.

[0098] In any of the above embodiments, the aerosol generator comprises a single second type of electrical contact.

[0099] In any of the embodiments described above, a single second type of electrical contact is shared among each of the resistance heating elements.

[0100] In any of the above embodiments, the resistive heating element is formed by at least one of the following: cutting the resistive heating layer, chemically etching the resistive heating layer, forming or pressing the resistive heating layer into the substrate, or printing the resistive heating layer.

[0101] In any of the above embodiments, the resistance heating layer is in the form of a foil.

[0102] According to one aspect, Aerosol generating materials and A resistance heating layer comprising a resistance heating element configured to generate an aerosol by heating at least a portion of an aerosol generating material, The first type of electrical contact, The second type of electrical contact, Equipped with, An aerosol generator for an aerosol supply device is provided, wherein the resistive heating element is at least a portion of the conductive path between a first type of electrical contact and a second type of electrical contact.

[0103] The aerosol generator may include an aerosol generating layer containing an aerosol generating material. The aerosol generating layer may be located on a resistance heating layer.

[0104] According to one embodiment, an aerosol supply system is provided that is configured to receive an aerosol generator or an article for any of the above-mentioned aerosol supply devices.

[0105] According to one embodiment, an aerosol supply system is provided comprising an aerosol generator or an article for any of the above-mentioned aerosol supply devices, and any of the above-mentioned aerosol supply devices.

[0106] Any device, article, or system in any embodiment may have any of the features specified in relation to other embodiments. [Brief explanation of the drawing]

[0107] Here, various embodiments will be described as mere examples, with reference to the attached drawings. [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 perspective view of the partially disassembled article, showing the aerosol generator reversed from its assembled orientation and spaced apart from the 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 shows the aerosol generator that has been formed. [Figure 24] This shows the aerosol generator that has been formed. [Figure 25] This shows the aerosol generator that has been formed. [Figure 26] This is a schematic perspective view of an aerosol generator. [Figure 27]Figure 26 is a schematic perspective view of an aerosol-forming article equipped with an aerosol generator. [Figure 28] This is a schematic perspective view of an aerosol supply device. [Figure 29] Figure 28 is a partially transparent perspective view of the aerosol supply device. [Figure 30] This is a schematic perspective view of an aerosol supply system comprising the aerosol-forming article shown in Figure 27 and the aerosol supply device shown in Figure 28. [Figure 31] Figure 30 is a partially transparent perspective view of the aerosol supply system. [Figure 32a] This is a schematic perspective view of an aerosol generator. [Figure 32b] Figure 32a is a schematic perspective view of an aerosol-forming article equipped with the aerosol generator shown in Figure 32a. [Figure 33] Figure 32b is a schematic perspective view of an aerosol supply system comprising an aerosol-forming article and an aerosol supply device. [Figure 34] This is a schematic perspective view of an aerosol-forming article. [Figure 35] Figure 34 is a cross-sectional perspective view of an aerosol supply system comprising an aerosol-forming article and an aerosol supply device. [Figure 36] This is a schematic perspective view of an aerosol generator. [Figure 37] Figure 36 is a schematic cross-sectional view of an aerosol-forming article equipped with an aerosol generator. [Figure 38] Figure 37 is a schematic perspective view of an aerosol-forming article. [Figure 39] Figure 38 is a partially transparent perspective view of an aerosol supply system comprising an aerosol-forming article and an aerosol supply device. [Figure 40] Figure 39 is a schematic perspective view of the aerosol supply system. [Figure 41] This is a schematic perspective view of the receptacle base of an aerosol supply device. [Figure 42] Figure 41 is a schematic cross-sectional view of an aerosol supply system comprising a receptacle base and an aerosol-forming article. [Modes for carrying out the invention]

[0108] As used herein, the term “delivery mechanism” is intended to encompass a system for delivering a substance to a user, and includes a non-combustible aerosol delivery system that releases compounds from an aerosolizable material without burning the aerosolizable material, such as a hybrid system that generates an aerosol using a combination of an electronic cigarette, a tobacco heating product, and an aerosolizable material; and an article comprising an aerosolizable material and configured for use in one of these non-combustible aerosol delivery systems.

[0109] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or components of the materials) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0110] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0111] In some embodiments, the non-combustion aerosol supply system is an electronic cigarette, also known as a vaporization 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.

[0112] 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.

[0113] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates aerosols 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.

[0114] 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.

[0115] 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.

[0116] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device for a non-combustible aerosol supply system, may include a power source and a control device. The power source may be, for example, an electric power source.

[0117] In some embodiments, the non-combustion aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a suction port, a filter, and / or an aerosol modifier.

[0118] 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, a wrapping material, a filter, a suction nozzle, and / or an aerosol modifier.

[0119] 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 energized by any other means. 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 fragrances.

[0120] In some embodiments, the delivered substance includes an active substance (sometimes referred to herein as an active compound).

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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.

[0125] The aerosol-generating film may be continuous. For example, the film may include continuous material sheets, or it may be a continuous material sheet.

[0126] 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.

[0127] The aerosol-generating film may be formed by combining a binder such as a gelling agent with a solvent such as water, an aerosol-forming agent, and one or more other components such as 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.

[0128] The slurry may be heated to remove at least about 60% by weight, 70% by weight, 80% by weight, 85% by weight, or 90% by weight of the solvent.

[0129] 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.

[0130] 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.

[0131] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0132] The material may be present on or within a support in order 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 contain these materials.

[0133] An aerosol supply device can receive an article containing an aerosol-generating material for heating. In this context, “article” means a component that contains or is contained with an aerosol-generating material at the time of use, which is heated to volatilize the aerosol-generating material, and optionally, other components at the time of use. The user may insert the article into or onto the aerosol supply device before the article is heated to generate an aerosol, and then the user inhales the aerosol.

[0134] 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.

[0135] Consumables are articles containing aerosol-generating material or articles consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. Consumables may also include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapping material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may include, for example, a material that can be heated by electrical conductivity.

[0136] 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 source and a control device (or control circuit). The power source may comprise a power source such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol supply device may also comprise an aerosol generating component. However, in other implementations, the aerosol product may comprise the aerosol generating component partially or entirely.

[0137] 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). Figure 2 shows the article 300 removed from the aerosol supply device 200. Figure 3 shows the aerosol generator 304 of the article 300, along with a perspective view of a first side view 306, and a portion of the second side view 307 is shown in a perspective view in Figure 4.

[0138] 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.

[0139] The aerosol supply system 100 may be elongated and 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 the aerosol generated by the aerosol supply system 100 is used by the user for inhalation, and a distal end 104 that is furthest from the user during use.

[0140] The proximal end may also be called the “oral end.” Thus, the aerosol supply system 100 defines a proximal direction that is directed toward the user during use. Furthermore, the aerosol supply system 100 similarly defines a distal direction that is directed toward 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 toward each other in the proximal-distal direction along the longitudinal axis. The longitudinal axis extends from the oral end 102 to the distal end 104. The transverse direction is perpendicular to the longitudinal axis. The transverse direction is parallel to the plane of the aerosol generator 304, which will be described later.

[0141] Article 300 is received by an aerosol supply device 200. The configurations of article 300 and the aerosol supply device 200 may vary. In this embodiment, the aerosol supply device 200 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 wall 212. The configuration of the receptacle 208 may vary depending on the configuration of article 300.

[0142] The aerosol supply device 200 may be provided with one or more user-operable control elements 224, such as buttons or switches, which can be used to operate the aerosol supply system 100. For example, a user may start the system 100 by pressing a control element 224.

[0143] 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 into which an article 300 can be inserted. In 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 on the longitudinal side wall of the device 200 and / or may be closed during use by another feature of the device 200. In this configuration, the article 300 defines a mouthpiece 310 at its proximal end 308. In other embodiments, the device 200 defines a mouthpiece. During use, the user places their mouth over the mouthpiece.

[0144] Device 200 defines a longitudinal axis that may extend when article 300 is inserted into device 200. The opening 214 is aligned on the longitudinal axis. The longitudinal axis may also be the axis through which article 300 is inserted into device 200. The longitudinal axis may be considered the receiving axis of device 200. Article 300 may similarly have a longitudinal axis through which it is inserted into the device, and this axis may be considered the insertion axis.

[0145] The aerosol supply device 200 includes a power source 220. The power source 220 may be a battery, for example, a rechargeable battery. The device 200 also includes a control circuit 222 which functions as a control unit and includes a processor and memory.

[0146] As will be described in detail below, the heating system 110 is configured to heat the aerosol-generating material 302 of article 300. Article 300 in the embodiment is a consumable and replaceable 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 source 220 and a control circuit 222.

[0147] The aerosol generator 304 forms part of article 300. The aerosol generator 304 includes a heating array 312 configured to heat an aerosol-generating material 302, such as at least one of a film and a gel, to generate an aerosol. The aerosol-generating material may also be called an aerosolizable material.

[0148] The heating array 312 is a resistive heating array. In the embodiment, the heating element or each heating element is a resistive heating element, as will be described in detail below. In such an array, the heating system 110 includes a resistive heating generator that includes a component for heating the heating array 312 via a resistive heating process. In this case, current is applied directly to the resistive heating element, and the resulting current flow within the heating element acts as a heating component, heating the heating element by Joule heating. The resistive heating element includes a resistive material configured to generate heat when a suitable current passes through the resistive heating element, and the heating array 312 includes electrical contacts for supplying current to the resistive material. The presence of the resistive heating array 312 enables a compact array. Resistive heating provides an efficient configuration.

[0149] When the aerosol supply system 100 is in use, air is drawn into an air inlet 314 of the article 300, also called the article inlet, as indicated by arrow 316. The air inlet 314 is located at the distal end of the article 300. In embodiments, the air inlet 314 may have a different configuration, for example, on the side. The airflow from the article 300 to the air inlet 314 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 through the aerosol outlet 318, as indicated by arrow 319. In embodiments, the aerosol outlet 318 is located in the mouthpiece of the article 300 so that the aerosol is drawn directly from the article 300 to the user's mouth of the device 10.

[0150] In some exemplary embodiments, the aerosol supply system comprises two main components: a control section that forms a reusable component, and a consumable section that forms a replaceable or disposable component, 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 component may be detachably connected at an interface. The consumable component is detachable and replaceable, for example, when the consumable component is used, and the control section may be reused with a different consumable component.

[0151] 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 an air inlet of a control section, passes through an interface, and exits a consumable part.

[0152] As schematically shown in Figure 5 and described in detail below, article 300 has article electrical contact configuration 320. In this embodiment, the electrical contact configuration 320 is formed by an aerosol generator 304. The electrical contact configuration 320 includes a heater electrical contact 322. The heater electrical contact 322 may also be known as a heater or article contact. The aerosol supply device 200 includes an electrical connector 230. The electrical connector 230 includes a connector electrical contact 232. The connector electrical contact 232 may also be known as a connector or device contact. The article electrical contact configuration 320 is configured to communicate electrically with the device electrical connector 230.

[0153] The configuration of article 300 may vary. Article 300 comprises a body 324. The body 324 is hollow. The body 324 defines a flow path 326 (see Figure 6) through article 300. The flow path 326 extends between an air inlet 314 and an aerosol outlet 318. The flow path 326 is defined by an internal space within the article through which air and / or aerosols can flow. The flow path 326 is defined within the body 324. An aerosol generator 304 or each aerosol generator 304 partitions the flow path 326. The aerosol generating material 302 is exposed to the flow path 326. The aerosol generating material 302 is exposed to the internal space. In the embodiment, the internal space comprises two or more chambers.

[0154] The air inlet 314 includes an opening 315. The opening 315 is formed in the main body 324. In embodiments, the opening is formed in another component of the article 300, for example, an aerosol generator 304 or another wall feature. The aerosol outlet 318 includes an outlet opening 317. The outlet opening 317 is formed in the main body 324. In embodiments, the outlet opening 317 is formed in another component of the article 300, for example, an aerosol generator 304 or another wall feature.

[0155] As shown in Figure 6, article 300 comprises two aerosol generators 304 that form an aerosol generator array. The number of aerosol generators 304 may vary. Each aerosol generator 304 contains an aerosol generating material 302. The aerosol generating material 302 is exposed to a channel 326. In embodiments, article 300 comprises a single aerosol generator 304. One of the aerosol generators 304 is described in detail, and such details are applicable in embodiments to one or more further aerosol generators 304.

[0156] The aerosol generator 304, or each aerosol generator 304 and the main body 324, are formed in a stacked configuration. In embodiments, other arrangements, such as a tubular arrangement of articles, are envisioned. In such a tubular arrangement, the aerosol generator 304 defines the tubular arrangement. The tubular shape may include a circular cross-section, an elliptical cross-section, and other polygonal shapes.

[0157] In this embodiment, as shown in the figure, article 300 has a flat configuration. That is, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to both the length and the width, where the length is greater than or equal to the width, and the width is greater than the depth. Other configurations are also conceivable.

[0158] Figure 6 is a partially exploded schematic perspective view of article 300 of Figure 2, in which the aerosol generator 304 is shown inverted from its assembled orientation and spaced apart from other components. Article 300 comprises a first aerosol generator, a body 324, and a second aerosol generator. The body 324 spacees the first and second aerosol generators 304 apart. The first and second aerosol generators 304 enclose an internal space defined by the body 324 through which air and / or aerosols can flow. The aerosol-generating materials 302 of the first and second aerosol generators 304 face each other and are exposed to the internal space. When assembled, the first and second aerosol generators 304 sandwich the body 324. In the embodiment shown in Figure 6, at least the first and second aerosol generators 304 and the main body have equal planar areas. In the embodiment, one or more of the first and second aerosol generators 304 and the main body 324 have a greater length and / or width. In the embodiment, one of the first and second aerosol generators 304 is replaced with a blank panel. The main body 324 comprises a main body layer. The main body may comprise multiple main body layers. The main body layers may be formed in a layered manner and arranged to define features of the article 300, such as an air inlet 314 and an aerosol outlet 318.

[0159] The wrap surrounds the article 300 and forms part of the article 300. The wrap may comprise a sheet. The wrap functions as a fixing sleeve. The aerosol generator 304 or each aerosol generator 304 protrudes from the wrap at its distal end. The exposed electrical contact area 323 of the heater contact 322 is exposed at its distal end. Other configurations are conceivable, for example, at least one exposed electrical contact area 323 may be additionally or alternatively defined along the secondary longitudinal surface or edge of the article 300 on the principal surface of the article defined by the aerosol generator 304.

[0160] The aerosol generator 304 is schematically shown in a cross-sectional view in Figure 7. The aerosol generator 304 is an implementation of the aerosol generator 304 of the aerosol supply system 100 described above.

[0161] 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 comprises a resistance heating layer 340, which in 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 embodiments, the aerosol generating layer 330 is in indirect contact with the resistance heating layer 340. The resistance heating layer 340 may in embodiments 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. The resistance heating elements 342 or each resistance heating element 342 forms at least a portion of the conductive path between a pair of electrical contacts 322. The resistance heating element 342, or each resistance heating element 342, provides a conductive path for resistively heating at least a portion of the aerosol generating material 302 to generate an aerosol. In embodiments, the aerosol generating material 302 is in the form of a film or a gel.

[0162] The resistance heating layer 340 is formed as a conductive layer. In this embodiment, this layer takes the form of at least one of a metal layer such as an aluminum layer or a non-metallic material such as graphene. The resistance heating layer 340 is in the form of a foil, for example, an aluminum foil.

[0163] The aerosol generator 304 comprises a support 350. In this embodiment, the support 350 includes paper or card material. The support 350 provides structural support for the aerosol generator 304. The resistance heating layer 340 may be 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.

[0164] 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 generation layer 330.

[0165] Article 300 may comprise a laminate 354 having a resistance heating layer 340 and a support layer 350. In 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 discontinuous parts may include one or more of dots, strips, helices, or other shapes.

[0166] 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. In this embodiment, the support layer 350 is omitted.

[0167] Figure 8 shows one of the resistance heating elements 342. The resistance heating layer 340 comprises multiple resistance heating elements 342. In this embodiment, the resistance heating layer 340 comprises a single resistance heating element 342.

[0168] The multiple heating elements 342 may be formed as an array 344, as shown in Figure 9. Other configurations are also possible.

[0169] The resistive heating element 342 includes a resistive heating path. The resistive heating path is formed by a conductive path. The resistive heating path is nonlinear. The resistive heating path is intricate. The configuration of the resistive heating path may vary. The electrical resistance of the heating element 342 may depend on the properties of the resistive heating path in the conductive layer, such as the length, width, thickness, and arrangement of the path.

[0170] The resistive heating element 342 extends between a first type of electrical contact 360 and a second type of electrical contact 365. The first type of electrical contact 360 is configured to provide a positive contact, and the second type of electrical contact 365 is configured to provide a negative contact. Current flows through the path between the first type of electrical contact 360 and the second type of electrical contact 365. The contact arrangement may be reversed. The first and second types of electrical contacts 360, 365 constitute the heater electrical contact 322. The first and second types of electrical contacts 360, 365 form at least a portion of the article electrical contact configuration 320.

[0171] The winding or meandering nature 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.

[0172] 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.

[0173] 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.

[0174] As described in detail below, the conduction path of the resistive heating element 342 in the embodiment is formed by defining at least one electrically insulating barrier 346 within the resistive heating layer 340. In the embodiment, the electrically insulating barrier 346 is formed by cutting an electrically insulating barrier limiting portion (i.e., an electrically insulating portion), such as a gap, channel, or slot, in a sheet formed of the conductive material to form the resistive heating layer 340. In the embodiment, the conductive element 342 is pre-formed to define the resistive heating element 342 or each resistive heating element 342, and then applied to the support 350. In the embodiment, the resistive heating layer 340 is applied to the support 350, and then the resistive heating element 342 or each resistive heating element 342 is defined within the resistive heating layer 340. The resistive heating element 342 or each resistive heating element 342 defining the resistive heating layer 340 may be a printed heater.

[0175] At least one electrical insulating barrier 346 defines first and second types of electrical tracks 361, 366.

[0176] In some embodiments, the track width of the resistive heating element 342 or each resistive heating element 342 is in the range of 0.5 mm to 1 mm (in two exemplary prototypes, the widths are 0.93 mm and 0.72 mm, respectively), and the gap between tracks is less than approximately 0.25 mm (in the same two exemplary prototypes, the gaps are 0.2 mm and 0.05 mm, respectively). The resistive heating element 342 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 the resistive heating element 342 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 μohms cm, the resistance of the path was calculated to be approximately 1 ohm. In one exemplary embodiment, the resistance was measured between 0.83 and 1.31 ohms.

[0177] As shown in Figure 9, the resistive heating layer 340 may be formed on multiple resistive heating elements generally indicated by reference numbers 342a, 342b, 242c, 342d, and 342e. Each of the resistive heating elements 342a to 342e extends from one of the respective first type of electrical contacts, generally indicated by reference numbers 360a, 360b, 360c, 360d, and 360e, to a single second type of electrical contact 365. The number of electrical contacts may vary. Thus, the resistive heating elements 342a to 342e extend between individual first type electrical contacts and a common second type of electrical contact.

[0178] Each of the resistance heating elements 342a to 342e provides a conductive path for resistively heating a portion of the aerosol generating material 302 to generate an aerosol in the respective part of the aerosol generator 304.

[0179] The first type of separate electrical contacts 360a to 360e allows for the individual supply of current to each of the multiple resistive heating elements 342a to 342e. This allows for the control of heating different regions 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 separately. Thus, for example, five aerosol sprays can be produced from a single consumable incorporating a single aerosol generator 304, and ten aerosol sprays can be produced from a single consumable incorporating two aerosol generators 304.

[0180] In an exemplary resistance heating layer 340, a plurality of first type electrical contacts 360a to 360e, for example, positive electrode electrical connections, and a single second type electrical contact 365, for example, negative electrode electrical connection, are provided. This is not essential for all implementation configurations. For example, it is also possible to provide a plurality of second type contacts. In the embodiment, each resistance heating element 342a to 342e comprises a corresponding first type electrical contact 360 and a corresponding second type electrical contact 365.

[0181] 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 may facilitate power connection, but of course many other configurations are possible, some of which will be described further below.

[0182] Figure 10 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304 according to an exemplary embodiment, generally referred to as reference number 400.

[0183] The method or algorithm 400 begins with an operation 402 in which a resistive heating layer is formed on one or more heating elements (e.g., multiple heating elements), each resistive heating element extending from a first type of electrical contact to a second type of electrical contact. The heating elements or each heating element may be used to provide a conductive path for resistively heating a portion of an aerosol-generating material to generate an aerosol. The formation of the resistive heating elements or each resistive heating element may occur before or after coating the resistive heating layer on a support, where the support is present. The resistive heating layer may be bonded to the support or mounted or formed on the support in different configurations.

[0184] In operation 404, the formed resistance heating layer is placed in contact with the aerosol generating layer, and the aerosol generating layer incorporates the aerosol generating material. The aerosol generator 304 described above may be generated using algorithm 400.

[0185] 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, dispensing, or some other method. In an exemplary implementation of operation 64, the aerosol generating layer 330 is positioned on the resistance heating layer 340 as indicated by arrow 406.

[0186] Figure 12 shows a resistance heating layer 340 formed according to an exemplary embodiment. The resistance heating layer 340 is in the process of being cut using a laser cutter 408. Cutting the resistance heating layer 340 can be used to form the path of the heating element described herein. The use of a laser cutter 408 (or any other cutting process) is not the only way in which the resistance heating layer 340 described herein can be produced. Several exemplary methods are described below.

[0187] Figure 13 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, generally referred to as reference no. 410. Method or algorithm 410 begins with operation 412, in which a resistance heating layer is provided. In operation 414, one or more resistance heating elements are formed within the resistance heating layer by chemical etching of the resistance heating layer. Operations 412 and 414 are exemplary implementations of operation 402 of method 400 described above. Next, an aerosol generating material is placed on the resistance heating layer, thereby performing operation 404 described above.

[0188] Figure 14 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, which is shown as a whole by reference no. 418. The method or algorithm 418 begins with operation 420, in which one or more heating elements are formed by printing a resistive heating layer at least partially. Thus, operation 420 is an exemplary implementation of operation 62 of algorithm 402 described above. Next, the aerosol generating material is placed on the resistive heating layer, thereby performing operation 404 described above.

[0189] The cutting, etching, and printing methods described above are provided as examples, and other additional or alternative methods are also possible. For example, a so-called “hot foil” approach can be used, in which the heating element is fabricated from a resistive heating layer and then assembled / bonded onto a support. Even further techniques, such as die-cutting, can also be used. Furthermore, two or more techniques can be combined (for example, conductivity can be imparted to the connection traces by adding conductive materials such as additional foil or printed 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.

[0190] Figure 15 is a flowchart illustrating a method or algorithm of operation according to an exemplary embodiment, generally 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 in an instance of operation 426. In response to the command to initiate heating, a determination is made as to whether a heating element is available (operation 428). As described above, multiple heating elements may be provided. Operation 428 may also involve a determination of which heating element was used and / or which corresponding available aerosol generating material was consumed.

[0191] If a heating element is available, the algorithm proceeds to operation 430, where the available heating element is used. As described above, the heating elements may be individually controllable, for example, by supplying power to each individual heating element. Once operation 430 is complete, the algorithm terminates with operation 432. If, in operation 428, it is determined that there are no available heating elements, 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.

[0192] Figure 16 shows a resistance heating layer 340 formed according to an embodiment. The resistance heating layer 340 is cut using a laser cutter 408, but other methods such as chemical etching or printing can also be used as described above. Cutting the conductive layer 340 forms the heating element described herein.

[0193] In the embodiment shown in Figure 16, the path to be cut is a straight path that extends along the length of the conductive layer 120.

[0194] 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 a first type of electrical contact 360, e.g., a positive electrical connection, to one of a second type of electrical contact 365, e.g., a negative electrical contact. In such an embodiment, both types of electrical contacts are provided at the same end of the resistance heating layer 340 and adjacent to each other. In such an arrangement, there is no common second type of electrical contact as in other embodiments; instead, each heating element has separate first and second type electrical contacts.

[0195] 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. Even when linear paths are provided, an increase in electrical resistance may be achieved by providing a sawtooth path that functions as an intricate path. Note that the paths of any other embodiments described herein may also be sawtooth.

[0196] 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 within a lamination of body layers 325. The body layers 325 form a laminate. In this embodiment, the body layers 325 are card layers. Other suitable materials may be used. The body layers 325 are configured to define the features of article 300. In this embodiment, at least one body layer has a gap that defines an air inlet 315. The gap defines an opening 314.

[0197] 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 positive electrical connections to each of, for example, a plurality of heating elements 342, and a single second type of electrical contact 365 that provides a common negative electrical connection to the plurality of 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.

[0198] 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, allowing it to make contact with the device electrical connector 230. The heater contact 322 is on the opposite side of the resistive heating layer 340 from the resistive heating element 342. Other configurations are also possible.

[0199] The support layer 350 is located between the inner portion and the outer portion of the resistance heating layer 340.

[0200] A bent portion 370 is formed in the resistance heating layer 340. The bent portion 370 defines the heater contact 322. The bent portion 370 shown in Figures 2 to 4 and Figure 19 extends perpendicular to the longitudinal axis of the aerosol generator 304. The bent portion 370 defines the flap 372. The heater contact 322 is located on the flap 372. The flap defines the contact panel. The remaining blank portion defines the main panel.

[0201] In an embodiment having a support layer 350, the support layer 350 of the embodiment is bent. The substrate 352 is bent at the bent portion 370. In the embodiment, the support layer 350 ends at the bent portion. In the embodiment, the bent portion 370 extends parallel to the longitudinal axis of the aerosol generator 304.

[0202] The bent portion of the resistance heating layer 340 is fixed in the bent position. In this embodiment, this bent portion is joined, for example, by adhesive. Other fixing means are also conceivable.

[0203] The bent portion 370 defines a first type of exposed contact area 362. The bent portion 370 defines a second type of exposed contact area 367. Electrical tracks 361 and 366 are electrically connected across the bent portion 370. The 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 surface of the resistance heating layer 340. The portions of the first type of electric track 361 and the second type of electric track 366 extend to the first side surface of the resistance heating layer 340. In this embodiment, the resistance heating element extends from the bent portion 370. Other configurations are also possible.

[0204] The aerosol generator 304 comprises multiple connector electrical contacts 232 of an electrical connector 230. The configuration of the device connector 230 depends on the configuration of the heater contacts 322 of the aerosol generator 304. In embodiments such as the aerosol generator shown in Figure 19, the aerosol generator 300 comprises multiple heater contacts 322, each comprising one of a plurality of first type heater contacts 360 and one of a second type heater contacts 365. Article 300 comprises 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 of which are 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 a connector array configured to supply power to connectors 230a and 230b. The aerosol supply device 200 may operate the method as described above, for example.

[0208] Figure 22 is a flowchart showing a method or algorithm for forming an aerosol generator 304 according to an exemplary embodiment, generally referred to as reference number 440.

[0209] The method or algorithm 440 begins with 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 of 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 herein.

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

[0211] Operations 442 and 444 in method or algorithm 440 are the same as (or may be identical to) operations 402 and 404 in method or algorithm 400 described above.

[0212] In operation 446, at least one electrical contact of the first type 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 electrical contact of the second type is provided on the resistance heating layer. The method of formation may be any of the methods described above.

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

[0214] In the embodiment, a first type of electrical contact (e.g., a positive electrode connection) is provided along a first edge of the resistance heating layer. In the embodiment, a second type of electrical contact (e.g., a negative electrode 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 an embodiment, the support layer is bent together with the resistance heating layer. In an embodiment, the resistance heating layer is bent so that first and second types of electrical contacts are provided adjacent to each other, as will be described 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 this embodiment, the blank defines fold lines where the bends are created during the formation of the aerosol generator. The aerosol generator 304 blank 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 electrode 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 the embodiment, the contacts are spaced apart from the edge. As described above, each of the multiple heating elements extends from the first type electrical contact to the second type electrical contact.

[0219] The laser cutter 408 cuts the resistance heating layer 340, forming the heating elements 342 or the paths for each heating element 342. As described above, laser forming or any other cutting process is not the only way to produce the resistance heating layer 340 described above. Some exemplary alternative methods include chemical etching and printing.

[0220] As shown in Figure 24, the aerosol generation layer 330 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 folded portion is formed parallel to the longitudinal direction of the aerosol generator 304. Two folded portions 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 generation layer 330 is located on the first panel 375. Figure 25 shows the folded aerosol generator 304.

[0221] Figure 26 shows another embodiment of the aerosol generator 304 of article 300. The aerosol generator 304 has many of the features of the aerosol generator 304 shown in Figure 3, and a repeated description of those features is omitted, so the differences will be described here. In other examples, the aerosol generator 304 may have any of the features of the aerosol generator 304 described above with respect to other figures. As previously stated, the aerosol generator 304 comprises a resistance heating layer 340 and an aerosol generating layer 330.

[0222] In this embodiment, the resistance heating layer 340 further comprises an extended portion 501 formed on the lateral surface of the resistance heating layer 340. The extended portion 501 is larger than the unextended portion of the resistance heating layer 340 and extends laterally from the longitudinal axis (i.e., in a plane parallel to the resistance heating layer 340 and perpendicular to the longitudinal axis of the article 300). In the longitudinal direction, the extended portion extends to the distal end 304 of the article 300. The extended portion 501 does not extend along the entire longitudinal range of the article 300. The unextended portion of the resistance heating layer 340 is at the mouth end of the article 300. The extended portion 501 thereby forms a stepped shape on the lateral surface of the aerosol generator 304.

[0223] The article 300 is configured to be inserted laterally into the article receiving portion 206 of the aerosol supply device 200. The stepped shape may allow the aerosol supply device 200 to hold the article 300 more securely (see Figure 30), and the extension portion 501 is received by the article receiving portion 206.

[0224] As described above, the resistance heating layer 340 further comprises a plurality of resistance heating elements 342 and a plurality of electrical contacts 360 365. In this embodiment, the electrical contacts 360 365 are positioned on the extension portion 501. The electrical contacts 360 365 and the resistance heating elements 342 are positioned on the first surface of the resistance heating layer. The aerosol generating layer 330 is positioned on the resistance heating layer 340 such that each of the resistance heating elements 342 is configured to heat at least a portion of the aerosol generating material to generate an aerosol. The resistance heating layer 340 extends beyond the aerosol generating layer 330. The extension portion 501 extends beyond the aerosol generating layer 330.

[0225] Figure 27 shows another embodiment of the aerosol-forming article 300, which includes the aerosol generator 304 shown in Figure 26. The aerosol-forming article 300 further comprises an article inlet 314 and a wrapping layer 502. The wrapping layer 502 forms the outer surface of the aerosol-forming article 300. The wrapping layer 502 is made of paper or cardboard. The wrapping layer 502 covers a second surface of the aerosol generator 304. The second surface is opposite to the first surface, which, as described above, is in contact with the aerosol-forming layer 330. The wrapping layer 502 has openings that expose a first type of electrical contact 360 so that the electrical contact 360 is accessible from the second surface. The article inlet 314 is located on the lateral side of the aerosol-forming article 300 in the extension portion 501.

[0226] Figures 28 and 29 show another embodiment of the aerosol supply device 200, and Figures 30 and 31 show another embodiment of the aerosol supply system 100. In this embodiment, the aerosol supply system 100 comprises the aerosol supply device 200 shown in Figure 28 and the aerosol-forming article 300 shown in Figure 27.

[0227] The aerosol supply device 200 and the aerosol supply system 100 have many of the features of the aerosol supply device 200 and the aerosol supply system 100 shown in Figure 1, respectively. A repeated explanation of these features will be omitted, and the differences will be described here. In other examples, the aerosol supply device 200 and the aerosol supply system 100 may have any of the features of the aerosol supply device 200 and the aerosol supply system 100 described above. As previously stated, the aerosol supply device 200 comprises a device body 202 that forms the external surface of the aerosol supply device 200. The device body 202 comprises an article receiving portion 206.

[0228] In this embodiment, the article receiving portion 206 is defined by a chamber having an opening on the lateral side of the aerosol supply device 200, the lateral side of the device being parallel to the lateral side of the article 300 in use. The aerosol-forming article 300 is configured to be inserted laterally into the article receiving portion 206, as described above. The article receiving portion 206 includes a notch 601, which is configured to expose a portion of the aerosol-forming article 300 inserted into the aerosol supply device 200. This means that a portion of the aerosol-forming article 300 is visible and accessible when the aerosol-forming article 300 is inserted into the article receiving portion 206.

[0229] Making a portion of the aerosol-forming article 300 visible to the user can be beneficial because it allows the user to observe when the article should be replaced, for example, by seeing the effects of heating on the article 300. The notch 601 may also provide an improved user experience by increasing the ease of inserting and removing the aerosol-forming article 300 from the aerosol supply device 200.

[0230] In this embodiment, the aerosol supply device 200 further comprises two or more electrical connectors 230, a compression seal 602, a puff sensor 603, and an inlet channel 604. The compression seal 602 is positioned on the first side of the article receiving portion 206 such that the compression seal 602 is parallel to the lateral surface of the aerosol-forming article 300. The compression seal 602 is formed of silicone. Alternatively, the compression seal 602 may be formed of foam or other compressible material.

[0231] The puff sensor 603 is positioned to communicate fluidly with the inlet channel 604. The puff sensor 603 is located inside the device body 202. The inlet channel 604 extends to the outer surface of the device body 202 to communicate directly with the surrounding environment. This allows air to flow into the inlet channel 604.

[0232] When the aerosol-forming article 300 is inserted into the aerosol supply device 200, the compression seal 602 is configured to seal the inlet channel 604 to the article inlet 314. The compression seal 602 is configured to be compressed by the article 300, thereby forming a better seal. By forming a seal between the inlet channel 604 and the article inlet 314, the puff sensor 603 can more accurately determine when the user has inhaled from the aerosol supply system 100 based on pressure fluctuations in the inlet channel 604. This improves the functionality of the aerosol supply system 100, making it possible, for example, to start heating when the user inhales or to track the number of times the user inhales.

[0233] As described above, the electrical connector 230 includes device contacts 232. In this embodiment, the electrical connectors 230 are positioned on both sides of the article receiving portion 206 such that the device contacts 232 make direct contact with at least some of the electrical contacts 360 365 when the article 300 is inserted into the aerosol supply device 200. Each electrical connector 230 is positioned on the inner wall of the article receiving portion 206 such that the device contacts 232 face inward, toward each other, and toward the article 300. By facing the device contacts toward each other, electrical connection to two resistance heating layers 304 is possible, and the article 300 comprises two such layers.

[0234] Figure 32a shows another embodiment of the aerosol generator 304. The aerosol generator 304 has many of the features of the aerosol generator 304 shown in Figure 3, and a repeated explanation of those features is omitted; instead, the differences will be described here. In other examples, the aerosol generator 304 may have any of the features of the aerosol generator 304 described above. As previously stated, the aerosol generator 304 comprises a resistance heating layer 340, a resistance heating element 342, and electrical contacts 360 365. In this embodiment, the resistance heating element 342 and the electrical contacts 360 365 are positioned on the first surface of the resistance heating layer 340.

[0235] Figure 32b shows another embodiment of the aerosol-forming article 300. The aerosol-forming article 300 has many of the features of the aerosol-forming article 300 shown in Figure 2, and a repeated description of those features is omitted; instead, the differences are described here. In other examples, the aerosol-forming article 300 may have any of the features of the aerosol-forming article 300 described above.

[0236] In this embodiment, the aerosol-forming article comprises an aerosol generator 304 shown in Figure 32a, a wrapping layer 502, and a support layer (not shown in Figure 32a). The wrapping layer 502 is positioned above the aerosol-generating layer 330 and covers the aerosol-generating layer. The support layer is located between the aerosol-generating layer 330 and the wrapping layer 502.

[0237] The resistance heating layer 340 extends laterally beyond the aerosol generating layer 330, the support layer, and the wrapping layer 502 such that at least a portion of the first surface of the resistance heating layer 340 is exposed to form a protruding portion 701. The protruding portion 701 is a portion along the side edge of the resistance heating layer 340 on the lateral surface of the aerosol forming article 300. The protruding portion 701 is provided with a first type of electrical contact 360 so that the first type of electrical contact 360 is exposed. In some embodiments, the aerosol forming article 300 may have two protruding portions 701 on different (e.g., opposite) sides of the aerosol forming article 300. These protruding portions 701 may be provided with a first type of electrical contact 360 and / or a second type of electrical contact 365, for example, the first type of electrical contact 360 being on the first protruding portion 701 and the second type of electrical contact 365 being on the second protruding portion 701.

[0238] The aerosol-forming article 300 may be configured for lateral or longitudinal insertion and may therefore be used with a longitudinal insertion device such as the aerosol supply device 200 shown in Figure 2, or a lateral insertion device such as the aerosol supply device 200 shown in Figure 28.

[0239] Figure 33 shows another embodiment of the aerosol supply system 100. The aerosol supply system 100 has many of the features of the aerosol supply system 100 shown in Figure 1, and a repeated explanation of those features is omitted; instead, the differences are described here. In other examples, the aerosol supply system 100 may have any of the features of the aerosol supply system 100 described above.

[0240] In this embodiment, the aerosol supply system 100 comprises an aerosol-forming article 300 shown in Figure 32a and an aerosol supply device 200. The aerosol supply device 200 comprises two or more electrical connectors 230, each electrical connector comprising device contacts 232. The device contacts 232 are configured to contact electrical contacts 360 located on a protruding portion 701 of the aerosol-forming article 300. The device connectors 232 are pogo connectors. Alternatively, the device connectors 232 may be other elastic connector configurations.

[0241] Since the electrical contacts 360 are exposed on the protruding portion 701 of the aerosol-forming article 300, the aerosol-forming article 300 can be made rotationally symmetrical and therefore can be inserted into the aerosol supply device 200 in different orientations, thereby improving the user experience. This configuration also eliminates the need for any bending during the manufacture of the aerosol-forming article 300, which is beneficial in terms of cost reduction and reduced manufacturing difficulty.

[0242] The electrical connector 230 may have a first set of device contacts 232a on a first lateral surface of the article 300 and a second set of device contacts 232b on a second lateral surface of the article 300. The first set of device contacts 232a may be oriented in a different direction from the second set of device contacts 232b. This allows the rotationally symmetric article 300 to be accepted in multiple orientations.

[0243] Figure 34 shows another embodiment of the aerosol-forming article 300. The aerosol-forming article 300 has many of the features of the aerosol-forming article 300 shown in Figure 2, and a repeated explanation of those features is omitted; instead, the differences will be described here. In other examples, the aerosol-forming article 300 may have any of the features of the aerosol-forming article 300 described above. As previously stated, the aerosol-forming article 300 comprises a wrapping layer 502, an aerosol generator 304, and a support layer (not shown in Figure 34).

[0244] In this embodiment, the aerosol-forming article 300 further comprises two notches 801. The notches 801 are formed from aligned, substantially rectangular cutouts in the resistance heating layer 340, the support layer, and the wrapping layer 502, i.e., the notches 801 pass completely through the aerosol-forming article 300. The notches 801 are positioned on the side edges of the aerosol-forming article 300.

[0245] The aerosol-forming article 300 is configured for lateral insertion and may therefore be used with a lateral insertion device such as the aerosol supply device 200 shown in Figure 35.

[0246] Figure 35 shows another embodiment of the aerosol supply system 100. The aerosol supply system 100 has many of the features of the aerosol supply system 100 shown in Figure 1, and a repeated explanation of those features is omitted; instead, the differences are described here. In other examples, the aerosol supply system 100 may have any of the features of the aerosol supply system 100 described above.

[0247] In this embodiment, the aerosol supply system 100 comprises an aerosol-forming article 300 shown in Figure 34 and an aerosol supply device 200. The aerosol supply device 200 includes two protruding keys 802 positioned on the first side surface of the article receiving portion 206. The protruding keys 802 are configured to be complementary to the notch 801 so that when the aerosol-forming article 300 is inserted into the aerosol supply device 200, the protruding keys 802 are inserted into the notch 801.

[0248] The notch 801 and protruding key 802 may allow for more secure retention of the aerosol-forming article 300 within the aerosol-supplying device 200. The notch 801 also ensures that the aerosol-supplying system 100 does not operate in other arrangements and that the aerosol-forming article 300 is inserted into the aerosol-supplying device 200 in the correct orientation, thereby improving the user experience.

[0249] Figure 36 shows another embodiment of the aerosol generator 304. The aerosol generator 304 has many of the features of the aerosol generator 304 shown in Figure 3, and a repeated explanation of those features is omitted; instead, the differences are described here. In other examples, the aerosol generator 304 may have any of the features of the aerosol generator 304 described above with respect to other figures. As previously stated, the aerosol generator 304 comprises a resistance heating layer 340 and an aerosol generating layer 330.

[0250] In this embodiment, the resistance heating layer 340 is formed in a half-pil shape. In other words, the resistance heating layer 340 comprises a substantially rectangular section and a substantially semicircular section (the curved edge of the semicircular section forms the edge of the resistance heating layer 340). The substantially semicircular section of the resistance heating layer shape defines the distal end 901 of the resistance heating layer. The rectangular section of the resistance heating layer shape defines the proximal end 902 of the resistance heating layer.

[0251] The resistive heating element 342 is located on the first side surface of the resistive heating layer 340. The resistive heating element 342 is arranged in a U-shape toward the proximal end 902 of the resistive heating layer 340 (so that the base of the U-shape is adjacent to the proximal end 902 of the resistive heating layer 340).

[0252] Figures 37 and 38 show another embodiment of the aerosol-forming article 300. The aerosol-forming article 300 has many of the features of the aerosol-forming article 300 shown in Figure 2, and a repeated description of those features is omitted; instead, the differences will be described here. In other examples, the aerosol-forming article 300 may have any of the features of the aerosol-forming article 300 described above. As described above, the aerosol-forming article 300 comprises a wrapping layer 502.

[0253] In this embodiment, the aerosol-forming article 300 comprises an aerosol generator 304 shown in Figure 36, a support layer 350, and a wrapping layer 502. The proximal and distal ends of the aerosol-forming article correspond to the proximal end 902 and distal end 901 of the resistance heating layer, respectively.

[0254] In this embodiment, the support layer 350 is positioned on the aerosol generator 304. The support layer 350 has a plurality of notches such that an article inlet 903 is formed at the distal end of the aerosol-forming article and an article outlet 904 is formed at the proximal end of the aerosol-forming article. The article inlet 903 has an opening that allows air to flow into the aerosol-forming article 300 so that air is drawn from the external environment to the center of the aerosol-forming article 300 when the aerosol supply system 100 is in use. The article outlet 904 has an opening that allows air to exit from the center of the aerosol-forming article 300 so that the generated aerosol may exit the aerosol-forming article 300 when the aerosol supply system 100 is in use.

[0255] In this embodiment, the wrapping layer 502 has an opening that exposes a first type of electrical contact 360. The first type of electrical contact 360 is positioned on the edge toward the proximal end of the aerosol-forming article 300.

[0256] Figures 39 and 40 show another embodiment of the aerosol supply system 100. The aerosol supply system 100 has many of the features of the aerosol supply system 100 shown in Figure 1, and a repeated description of those features is omitted; instead, the differences are described here. In other examples, the aerosol supply system 100 may have any of the features of the aerosol supply system 100 described above.

[0257] In this embodiment, the aerosol supply system 100 comprises an aerosol-forming article 300 shown in Figure 38 and an aerosol supply device 200. The aerosol supply device 200 has many of the features of the aerosol supply device 200 shown in Figure 2, and a repeated explanation of those features is omitted; instead, the differences will be described here. In other examples, the aerosol supply device 200 may have any of the features of the aerosol supply device 200 described above.

[0258] In this embodiment, the aerosol supply device further comprises a receptacle, the receptacle having an opening 907 for receiving at least a portion of the aerosol-forming article 300. The opening 907 is defined at the distal end of the aerosol supply device 200, and the distal end is defined relative to the proximal end of the aerosol supply device 200. To form the aerosol supply system 100, the aerosol-forming article 300 is inserted into the opening 907 such that the proximal end of the aerosol-forming article enters the aerosol supply device 200 first, as indicated by arrow 910. A portion of the aerosol-forming article 300 is visible when the aerosol-forming article is inserted into the opening 907 of the receptacle. The receptacle further comprises a notch 908 that exposes a portion of the aerosol-forming article when the aerosol-forming article 300 is inserted.

[0259] The aerosol supply device further comprises a plurality of electrical contacts (not shown in Figure 39). The plurality of electrical contacts are configured to contact the aerosol-forming article 300 inserted into the receptacle. More specifically, the plurality of electrical contacts are configured to electrically contact a first type of electrical contact 360 exposed on the aerosol-forming article 300 when the aerosol-forming article 300 is inserted into the opening 907 of the receptacle.

[0260] The aerosol supply device 100 further comprises a mouthpiece 909 through which a user can inhale aerosols generated from the aerosol-generating material of the aerosol-forming article 300. The aerosol supply device 100 comprises a device inlet 905, a device outlet 906, and a device channel. The device channel connects the device inlet 905 and the device outlet 906 so that the device inlet 905 and the device outlet 906 are in fluid communication. The device inlet 905 is in fluid communication with the article outlet 904 when the aerosol-forming article 300 is inserted. This means that when a user inhales over the mouthpiece 909, the aerosol generated by the aerosol-forming article 300 is drawn into the device inlet 905. The aerosol travels through the device channel and exits through the device outlet 906. The mouthpiece 909 is equipped with a device outlet 906 so that a user can receive aerosols from the mouthpiece 909. The mouthpiece 909 defines the proximal end of the aerosol supply device 200.

[0261] The aerosol supply device further comprises a pressure sensor (not shown in Figure 39) in fluid communication with the device flow path. In some embodiments, the pressure sensor may provide many functions similar to the puff sensor in Figure 29. In some embodiments, the pressure sensor may provide other functions, such as detecting when an aerosol-forming article 300 is inserted into the aerosol supply device 200.

[0262] Figure 41 shows the article receiving portion 206 of another embodiment of the aerosol supply device 200. The aerosol supply device 200 has many features of the aerosol supply device 200 shown in FIG. 2, and repeated descriptions of those features are omitted here, and the differences will be described here. In other examples, the aerosol supply device 200 may have any of the features of the aerosol supply device 200 described above with respect to other figures. As described above, the aerosol supply device includes an inlet flow path 604, a compression seal 602, and a puff sensor (not shown in FIG. 41). The inlet flow path 604 extends to the outer surface of the device 200 so as to be in direct fluid communication with the ambient environment. This allows air to flow into the inlet flow path 604. The puff sensor is in fluid communication with the inlet flow path 604 and may have any of the features of the puff sensor 603 described above with respect to other figures.

[0263] In this embodiment, the compression seal 602 includes a wall 1001 and a contact surface 1002. The wall 1001 extends from the surface of the aerosol receiving portion 206. The end of the wall 1001 defines the contact surface 1002.

[0264] In this embodiment, the contact surface 1002 is substantially flat. In some embodiments, the contact surface 1002 is rounded.

[0265] The article receiving portion 206 includes a stopper portion 1003. The stopper portion 1003 is arranged to limit the amount of compression that the aerosol-forming article can apply to the compression seal 602 when the aerosol-forming article 300 is inserted into the article receiving portion 206. The stopper portion 1003 includes at least one protrusion 1003 that extends into the article receiving portion 206. The at least one protrusion 1003 is arranged adjacent to the compression seal 602. In this embodiment, the stopper portion 1003 includes two protrusions 1003, and one of the protrusions 1003 is positioned on either side of the compression seal 602 within the article receiving portion 206.

[0266] Figure 42 shows a cross-section of another embodiment of the aerosol supply system 100. The aerosol supply system 100 has many features of the aerosol supply system 100 shown in FIG. 1, and repeated descriptions of those features are omitted, and differences will be described here. In other examples, the aerosol supply system 100 may have any of the features of the aerosol supply system 100 described above.

[0267] In this embodiment, the aerosol supply system 100 includes the aerosol supply device 200 shown in FIG. 41 and the aerosol forming article 300. The aerosol forming article 300 has many features of the aerosol forming article 300 shown in FIG. 2, and repeated descriptions of those features are omitted, and differences will be described here. In other examples, the aerosol forming article 300 may have any of the features of the aerosol forming article 300 described above. As described above, the aerosol forming article includes an article inlet 314. The compression seal 602 is configured to seal the inlet flow path 604 to the article inlet 314 when the article 300 is inserted into the article receiving portion 206 of the aerosol supply device 200. The compression seal 602 is deformed when the aerosol forming article 300 is inserted into the article receiving portion 206.

[0268] The aerosol forming article 300 includes a mouth-side end and a distal end, with a longitudinal axis extending between the distal end and the mouth-side end. The article inlet 314 is positioned at the distal end of the aerosol forming article 300.

[0269] The aerosol forming article 300 is configured to be inserted into the article receiving portion 206 in a direction parallel to the longitudinal axis.

[0270] The contact surface 1002 of the compression seal 602 contacts the aerosol forming article 300 and is arranged to seal the inlet flow path 604 to the article inlet 314. The wall 1001 of the compression seal 602 defines a seal air flow path. The seal air flow path extends between the inlet flow path 604 and the article inlet 314.

[0271] In this embodiment, at least a portion of the wall 1001 widens outward in the direction from the base of the wall 1001 toward the contact surface 1002, such that at least a portion of the sealing air passage increases the cross-sectional area between the base of the wall 1001 and the contact surface 1002. In other words, the compression seal 604 is molded so that the length of the wall 1001 is not parallel to the longitudinal axis of the aerosol-forming article 300.

[0272] In some embodiments, the wall 1001 is substantially straight such that the seal air passage has a substantially constant cross-sectional area along the length of the wall 1001. In other words, the compression seal 602 is molded such that the length of the wall 1001 is substantially parallel to the longitudinal axis.

[0273] The thickness of the wall 1001 varies along its length from the base to the contact surface 1002. More specifically, the thickness of the wall 1001 decreases along at least a portion of its length from the base towards the contact surface 1002. When the thickness of the wall 1001 decreases towards the contact surface 1002, the force required to deform the compression seal 602 when the wall 1001 comes into contact with the aerosol-forming article 300 is reduced. When the compression seal 602 deforms more easily, an effective seal is more likely to be created between the article inlet 314 and the inlet channel 604.

[0274] In some embodiments of the aerosol generators and different arrangements of articles described above, the aerosol-generating material is formed in a configuration other than as an aerosol-generating layer. In embodiments, the aerosol-generating material is in the form of an aerosol-generating segment. The aerosol-generating segment generally comprises a solid material. Such a solid material may be shredded tobacco. The aerosol-generating material may be arranged, for example, as an aerosol-generating segment and may comprise a plurality of individual aerosol-generating material pieces. The aerosol-generating material may also comprise individual tobacco material pieces. In embodiments, the aerosol-generating material comprises a plurality of strips, beads, or pellets. In embodiments, the aerosol-generating segment is a plug of material.

[0275] In the embodiments, the aerosol-generating segment includes a material body. The aerosol-generating material is non-liquid. In such embodiments, the material body includes a rod of the aerosol-generating material, for example, a tobacco rod. For example, the material body may include shredded tobacco material. The material body may be formed into a rod. In some embodiments, the material body includes shredded rag tobacco formed into a rod. The aerosol-generating material may include tobacco material. The aerosol-generating material may include extruded tobacco. The aerosol-generating material may include reconstituted tobacco.

[0276] The aerosol-generating material, formed as a solid material, may contain nicotine. The aerosol-generating material may contain tobacco, consist of tobacco, or consist essentially of tobacco. In some embodiments, the aerosol-generating material does not contain tobacco.

[0277] In any of the embodiments described above, heating of the article causes volatile compounds to be released relatively steadily into an inhalable medium. In one embodiment described above, the aerosol-generating segment is a plug of material. The article may include a mouth-end section. A tubular element may be located between the aerosol-generating material and the mouth-end section. The article may include a ventilation area in the mouth-end section. The mouth-end section may define a mouthpiece configured to be placed between the user's lips.

[0278] 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 embodiment is at least substantially cylindrical. In the embodiment, the aerosol-generating segment is at least partially enclosed by the resistance heating layer. In the embodiment, the resistance heating element extends within the aerosol-generating segment. The resistance heating element may extend around the aerosol-generating segment. In the embodiment, the resistance heating element surrounds the aerosol-generating segment. In some arrangements, at least a portion of the flow path through the article passes through the aerosol-generating segment. The aerosol-generating segment may define a portion of the air path. In the embodiment, a first type of electrical contact and a second type of electrical contact are exposed from the aerosol-generating segment.

[0279] The aerosol-generating material may include tobacco materials, such as those described herein, which include tobacco components. In the tobacco materials described herein, the tobacco components may include paper-reconstructed tobacco. The tobacco components may also include loose-leaf tobacco, extruded tobacco, and / or band-cast tobacco. The tobacco material may be provided in the form of shredded rag tobacco. Shredded rag tobacco can be formed from a mixture of forms of tobacco materials, for example, a mixture of one or more of paper-reconstructed tobacco, loose-leaf tobacco, extruded tobacco, and band-cast tobacco. In embodiments, the tobacco material includes paper-reconstructed tobacco, or a mixture of paper-reconstructed tobacco and loose-leaf tobacco. In the tobacco materials described herein, the tobacco material may include filler components. Filler components are generally components that do not contain non-tobacco components, i.e., raw materials derived from tobacco. Filler components may be non-tobacco fibers such as wood fibers or pulp or wheat fibers. Filler components may also be inorganic materials such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, and magnesium carbonate. Filler components may also be non-tobacco cast materials or non-tobacco extruded materials. The filler component may be present in an amount of 0% to 20% of the weight of the tobacco material, or 1% to 10% of the 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” means an agent that promotes aerosol formation. The aerosol-forming agent material may promote aerosol formation by promoting the initial vaporization and / or condensation of gas into inhalable solid and / or liquid aerosols. In some embodiments, the aerosol-forming agent material may improve the delivery of flavor from the aerosol-forming material. Generally, the aerosol-forming material of the present invention may include any suitable aerosol-forming agent material or agent, including those described herein.

[0280] 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 combined with fibrous material from the residue (usually after purification of the fibrous material and optionally with the addition of a portion of non-tobacco fibers) by depositing the extract onto the fibrous material. The recombination process is similar to the process of making paper.

[0281] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. an aerosol supply system, an aerosol supply device equipped with an article receiving portion, An aerosol-forming article having an oral end and a distal end, wherein the longitudinal axis extends between the distal end and the oral end, the aerosol-forming article is configured to be inserted laterally into the article receiving portion, and the later direction is perpendicular to the longitudinal axis, an aerosol supply system equipped with the following features.

2. The aerosol supply system according to claim 1, wherein a portion of the aerosol-forming article is visible when the aerosol-forming article is inserted into the article receiving portion.

3. The aerosol supply system according to claim 1 or 2, wherein the aerosol receiving portion includes a notch that exposes a portion of the aerosol-forming article.

4. The aerosol supply system according to any one of claims 1 to 3, wherein the aerosol-forming article is provided with an article inlet.

5. The aerosol supply system according to claim 4, wherein the article inlet is located on the lateral side of the aerosol-forming article, and the lateral side is offset laterally from the longitudinal axis.

6. The aerosol supply system according to claim 4 or 5, wherein the aerosol supply device comprises an inlet channel and a compression seal, wherein the compression seal is configured to seal the inlet channel to the article inlet.

7. The aerosol supply system according to claim 6, wherein the aerosol supply device comprises a puff sensor that is in fluid communication with the inlet channel.

8. The aerosol supply system according to claim 6 or 7, wherein the compression seal is positioned parallel to the lateral surface of the aerosol-forming article.

9. The aerosol supply system according to any one of claims 1 to 8, wherein the aerosol-forming article comprises an electrical contact formed on a first surface of the aerosol-forming article toward the lateral surface of the aerosol-forming article.

10. The aerosol supply system according to claim 9, wherein the electrical contact comprises a first type of electrical contact and a second type of electrical contact.

11. The aerosol-forming article comprises an aerosol generator, and the aerosol generator is Aerosol generating materials and A resistance heating layer comprising a plurality of resistance heating elements, wherein the aerosol generating material is located on the resistance heating layer, and each of the resistance heating elements is configured to heat at least a portion of the aerosol generating material to generate an aerosol; The aerosol supply system according to claim 9 or 10, comprising:

12. The aerosol supply system according to claim 11, wherein the resistance heating layer extends beyond the aerosol generating material such that the electrical contacts are exposed.

13. The aerosol supply system according to claim 12, wherein the aerosol supply device comprises a wrapping layer, the wrapping layer covers the aerosol generating material, and the resistance heating layer extends beyond the wrapping layer such that the electrical contacts are exposed.

14. The aerosol supply system according to any one of claims 11 to 13, wherein the aerosol generator comprises an aerosol generating layer containing the aerosol generating material, and the aerosol generating layer is located on the resistance heating layer.

15. The aerosol supply system according to any one of claims 1 to 14, wherein the aerosol-forming article comprises an extension portion extending laterally from the aerosol-forming article, and the extension portion is received by the article receiving portion.

16. Aerosol-forming article, An aerosol-forming article having an oral end and a distal end, the longitudinal axis of which extends between the distal end and the oral end, and configured to be inserted laterally into an aerosol supply device, wherein the later direction is perpendicular to the longitudinal axis.

17. an aerosol supply device, A receptacle having an opening for receiving at least a portion of an aerosol-forming article containing an aerosol-generating material into the aerosol supply device, The aerosol generated from the aerosol generating material can be inhaled by the user, and the mouthpiece defines the proximal end. Equipped with, The opening is defined at the distal end of the aerosol supply device relative to the proximal end of the aerosol supply device, An aerosol supply device comprising an electrical connector, wherein the electrical connector comprises a plurality of electrical contacts configured to contact the aerosol-forming article in the receptacle.

18. The aerosol supply device according to claim 17, wherein a portion of the aerosol-forming article is visible when the aerosol-forming article is inserted into the receptacle.

19. The aerosol supply device according to claim 18, wherein the receptacle has a notch that exposes a portion of the aerosol-forming article.

20. An aerosol supply system comprising an aerosol supply device according to any one of claims 17 to 19 and an aerosol-forming article.

21. The aerosol-forming article comprises an aerosol generator, and the aerosol generator is Aerosol generating materials and A resistance heating layer comprising a plurality of resistance heating elements, wherein the aerosol generating material is located on the resistance heating layer, and each of the resistance heating elements is configured to heat at least a portion of the aerosol generating material to generate an aerosol; The aerosol supply system according to claim 19, comprising:

22. The aerosol supply system according to claim 21, wherein the aerosol generator comprises an aerosol generating layer containing the aerosol generating material, and the aerosol generating layer is located on the resistance heating layer.

23. The aerosol-forming article comprises an article inlet and an article outlet, and the aerosol supply device comprises a device inlet, a device outlet, and a device flow path. The device flow path connects the device inlet and the device outlet such that the device inlet and the device outlet are in fluid communication. The aerosol supply system according to any one of claims 20 to 22, wherein the suction port is provided with the device outlet.

24. The aerosol supply system according to claim 23, wherein the device inlet is in fluid communication with the article outlet.

25. The aerosol supply system according to claim 23 or 24, wherein the device further comprises a pressure sensor that is in fluid communication with the device flow path.

26. The aerosol supply system according to any one of claims 21 to 25, wherein the resistance heating element is arranged in a U-shape on the first side surface of the resistance heating layer.

27. The aerosol supply system according to any one of claims 21 to 26, wherein the aerosol-forming article comprises an electrical contact formed on a first surface of the aerosol-forming article toward the proximal end of the aerosol-forming article.

28. The aerosol supply system according to claim 27, wherein the electrical contact comprises a first type of electrical contact and a second type of electrical contact.

29. an aerosol supply system, an aerosol supply device comprising an inlet channel and a compression seal, an aerosol-forming article having an article inlet, wherein the compression seal is configured to seal the inlet channel to the article inlet, an aerosol supply system equipped with the following features.

30. The aerosol supply system according to claim 29, wherein the aerosol-forming article comprises an oral end and a distal end, the longitudinal axis of which extends between the distal end and the oral end, and the article inlet is positioned at the distal end of the article.

31. The aerosol supply system according to claim 30, wherein the aerosol-forming article is configured to be inserted into the article receiving portion in a direction parallel to the longitudinal axis.

32. The aerosol supply system according to claim 29 or 30, wherein the compression seal comprises a contact surface arranged to contact the article and seal the inlet passage to the article inlet, and the contact surface is substantially flat.

33. The aerosol supply system according to any one of claims 29 to 31, wherein the compression seal comprises a contact surface arranged to contact the article and seal the inlet passage to the article inlet, and the contact surface is rounded.

34. The aerosol supply system according to any one of claims 29 to 33, wherein the compression seal comprises a wall, one end of the wall defining a contact surface positioned to contact the article and seal the inlet passage to the article inlet, and the wall defining a seal air passage.

35. The aerosol supply system according to claim 34, wherein the wall is substantially straight such that the sealing air passage has a substantially constant cross-sectional area.

36. The aerosol supply system according to claim 34, wherein at least a portion of the wall extends outward in a direction toward the contact surface from the base of the wall such that at least a portion of the sealing air passage increases the cross-sectional area between the base and the contact surface.

37. The aerosol supply system according to any one of claims 34 to 36, wherein the thickness of the wall varies along the length of the wall from the base to the contact surface.

38. The aerosol supply system according to claim 37, wherein the thickness of the wall decreases along at least a portion of the length of the wall in the direction from the base to the contact surface.

39. The aerosol supply system according to claim 38, wherein the article receiving portion comprises a stopper portion arranged to limit the amount of compression that the article can apply to the compression seal.

40. The aerosol supply system according to claim 39, wherein the stopper portion comprises at least one projection extending into the article receiving portion.

41. The aerosol supply system according to claim 40, wherein the at least one projection is positioned adjacent to the compression seal.

42. The aerosol supply system according to any one of claims 29 to 41, wherein the aerosol supply device further comprises a puff sensor that is in fluid communication with the inlet channel.

43. an aerosol supply device, An aerosol supply device comprising an inlet channel and a compression seal, configured to receive an aerosol-forming article having an article inlet, wherein the compression seal is configured to seal the inlet channel to the article inlet.

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