aerosol generator

Abstract

According to one embodiment, an article for an aerosol supply device is provided, comprising an aerosol-generating material and a resistance heating layer including a resistance heating element configured to heat at least a portion of the aerosol-generating material to generate an aerosol. The aerosol-generating material rests on the resistance heating layer. The article includes an exposed electrical contact area of ​​a first type of electrical contact configured to be electrically connected to an electrical connector of the aerosol supply device, and an exposed electrical contact area of ​​a second type of electrical contact configured to be electrically connected to an electrical connector of the aerosol supply device. The resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact. The article includes an opening in the article that defines an air inlet of a flow path through which an aerosol can flow. The exposed electrical contact area does not at least substantially overlap with the air passage through the article.

Description

Technical Field

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

Background Art

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

[0003] Aerosol supply systems covering the aforementioned devices or products are known. A common system uses a heater to generate aerosol from a suitable medium, which is then inhaled by a user. In many cases, to supply different aerosols for inhalation, it is necessary to replace or change the medium used. It is known to use a resistive heating system as a heater for generating aerosol from a suitable medium.

Summary of the Invention

[0004] According to one embodiment, an article for an aerosol supply device is provided, comprising an aerosol-generating material and a resistance heating layer including a resistance heating element configured to heat at least a portion of the aerosol-generating material to generate an aerosol. The aerosol-generating material rests on the resistance heating layer. The article includes an exposed electrical contact area of ​​a first type of electrical contact configured to be electrically connected to an electrical connector of the aerosol supply device, and an exposed electrical contact area of ​​a second type of electrical contact configured to be electrically connected to an electrical connector of the aerosol supply device. The resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact. The article includes an opening in the article that defines an air inlet of a flow path through which an aerosol can flow. The exposed electrical contact area does not overlap at least substantially with the air path through the article.

[0005] In the above embodiment, the aerosol generator includes an aerosol generating layer containing an aerosol generating material. The aerosol generating layer may be located on a resistance heating layer.

[0006] In the above embodiment, the article includes a support, and the resistance heating layer is located on the support.

[0007] In any of the above embodiments, the support includes a support layer.

[0008] In any of the above embodiments, the support is electrically insulating.

[0009] In any of the embodiments described above, the support includes at least one of paper and card.

[0010] In any of the above embodiments, the aerosol generating material is in direct contact with the resistance heating layer.

[0011] In any of the above embodiments, the aerosol generating material is indirectly in contact with the resistance heating layer.

[0012] In any of the embodiments described above, the resistance heating layer and the support layer define the substrate.

[0013] In any of the above embodiments, the aerosol generator includes a laminate comprising a resistance heating layer and a support layer.

[0014] In any of the above embodiments, the laminate includes an aerosol-generating material. In any of the above embodiments, the laminate includes an aerosol-generating layer.

[0015] In any of the above embodiments, the support layer includes a card layer.

[0016] In any of the embodiments described above, the article includes a body that defines at least a portion of the flow path, and the resistance heating layer is located on the body.

[0017] In any of the above embodiments, the air inlet may be defined by the main body.

[0018] In any of the above embodiments, the air inlet is formed by penetrating the main body.

[0019] In any of the above embodiments, the main body defines the main body wall, and the air inlet is defined by the main body wall.

[0020] In any of the embodiments described above, at least one of the exposed electrical contact areas of the first type and the second type of electrical contacts is supported by the body.

[0021] In any of the embodiments described above, each of the exposed electrical contact areas of the first and second types of electrical contacts is supported by the body.

[0022] In any of the above embodiments, each of the exposed electrical contact regions of the first type and the second type of electrical contacts overlaps the main body.

[0023] In any of the above embodiments, a majority area of each of the exposed electrical contact regions of the first type and the second type of electrical contacts overlaps the support.

[0024] In any of the above embodiments, the main body includes a main body layer.

[0025] In any of the above embodiments, the main body layer forms part of a laminate of main body layers including the main body.

[0026] In any of the above embodiments, the air inlet is defined by an area with a reduced number of main body layers.

[0027] In any of the above embodiments, the article includes a mouthpiece end and a distal end, and the air inlet is located at the distal end.

[0028] In any of the above embodiments, the article includes a mouthpiece end and a distal end, and the air inlet is located between the mouthpiece end and the distal end.

[0029] In any of the above embodiments, the air inlet is formed through the resistive heating layer.

[0030] In any of the above embodiments, the air inlet is defined in the support.

[0031] In any of the above embodiments, the article includes a substrate comprising a support layer and a resistive heating layer.

[0032] In any of the above embodiments, the air inlet is formed through the substrate.

[0033] In any of the above embodiments, the air inlet is defined through the aerosol-generating material. In any of the above embodiments, the air inlet is defined through the aerosol-generating layer.

[0034] In any of the embodiments described above, the air inlet is located upstream of each of the exposed electrical contact areas of the first and second types of electrical contacts.

[0035] In any of the embodiments described above, the air inlet is located downstream of each of the exposed electrical contact areas of the first and second types of electrical contacts.

[0036] In any of the embodiments described above, the air inlet is a first air inlet, and the article includes a second air inlet.

[0037] In any of the embodiments described above, the article includes a wrap configured to enclose at least a portion of the article, an air inlet is formed in the wrap, and at least one of the exposed electrical contact areas of the first type and the second type of electrical contacts does not overlap with the wrap.

[0038] In any of the embodiments described above, the air inlet is located on the same side of the article as at least one of the exposed electrical contact areas of the first type and the second type of electrical contacts.

[0039] In any of the embodiments described above, the air inlet is located on a different side of the article from at least one of the exposed electrical contact areas of the first type and the second type of electrical contacts.

[0040] In any of the above embodiments, the aerosol generating layer is a first aerosol generating layer, and the article includes a second aerosol generating layer containing an aerosol generating material.

[0041] In any of the embodiments described above, the second aerosol generation layer is located on the resistance heating layer.

[0042] In any of the embodiments described above, the resistance heating layer is a first resistance heating layer, and the article includes a second resistance heating layer.

[0043] In any of the embodiments described above, at least a portion of the second resistance heating layer forms a second resistance heating element, the second resistance heating element providing a conductive path for resistance heating at least a portion of the second aerosol generating material to generate an aerosol.

[0044] In any of the embodiments described above, the main body defines a space between the first aerosol generating layer and the second aerosol generating layer.

[0045] In any of the embodiments described above, the space defines at least a portion of the flow path.

[0046] In any of the above embodiments, the cross-section of the air inlet is one of the following: square, rectangular, circular, elliptical, cruciate, and capsule-shaped.

[0047] In any of the embodiments described above, the air inlet includes a grate.

[0048] In any of the embodiments described above, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and width, where the length is greater than or equal to the width and the width is greater than the depth.

[0049] According to one embodiment, an article for an aerosol supply device is provided, comprising an aerosol generating material and a resistance heating layer. The aerosol generating material is located on the resistance heating layer. At least a portion of the resistance heating layer forms a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol. The article includes a first type of electrical contact and a second type of electrical contact, the resistance heating element being at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact. The article includes a body that at least partially defines a flow path through which an aerosol can flow, and at least one of the first type of electrical contact and the second type of electrical contact is offset from the body.

[0050] In the above embodiment, the aerosol generator includes an aerosol generating layer containing an aerosol generating material. The aerosol generating layer may be located on a resistance heating layer.

[0051] In the above embodiment, the resistance heating layer forms a first type of electrical contact and a second type of electrical contact.

[0052] In the above embodiment, the resistance heating layer protrudes from the main body.

[0053] In the above embodiment, at least one of the first type of electrical contact and the second type of electrical contact protrudes from the main body.

[0054] In any of the above embodiments, the aerosol generator includes a support configured to support a resistance heating layer.

[0055] In any of the above embodiments, the support includes a support layer.

[0056] In any of the above embodiments, the support is electrically insulating.

[0057] In any of the embodiments described above, the support includes at least one of paper and card.

[0058] In any of the above embodiments, the aerosol generating material is in direct contact with the resistance heating layer.

[0059] In any of the above embodiments, the aerosol generating material is indirectly in contact with the resistance heating layer.

[0060] In any of the embodiments described above, the resistance heating layer and the support layer define the substrate.

[0061] In any of the above embodiments, the aerosol generator includes a laminate comprising a resistance heating layer and a support layer.

[0062] In any of the above embodiments, the laminate includes an aerosol-generating material. In any of the above embodiments, the laminate includes an aerosol-generating layer.

[0063] In any of the above embodiments, the support layer includes a card layer.

[0064] In any of the embodiments described above, the article includes a protruding panel that extends from the main body, and at least one of a first type of electrical contact and a second type of electrical contact is located on the protruding panel.

[0065] In any of the above embodiments, the protruding panel includes a support.

[0066] In any of the above embodiments, the protruding panel includes a resistance heating layer.

[0067] In any of the above embodiments, the protruding panel protrudes from the longitudinal end of the main body.

[0068] In any of the above embodiments, the protruding panel protrudes from the longitudinal side of the main body.

[0069] In any of the above embodiments, the substrate extends from the main body.

[0070] In any of the above embodiments, the substrate defines the protruding panel.

[0071] In any of the above embodiments, the article includes an opening in the body that defines an air inlet for the flow path.

[0072] In any of the embodiments described above, at least one of the first type of electrical contact and the second type of electrical contact does not overlap with the flow path.

[0073] 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.

[0074] In any of the embodiments described above, the support defines the exposed contact area of ​​the first type of electrical contact.

[0075] 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.

[0076] In any of the above embodiments, the aerosol generating material is a continuous aerosol generating material. In any of the above embodiments, the aerosol generating layer is a continuous aerosol generating layer.

[0077] In any of the above embodiments, the aerosol generating material is a discontinuous aerosol generating material. In any of the above embodiments, the aerosol generating layer is a discontinuous aerosol generating layer.

[0078] In any of the above embodiments, the aerosol generating material includes a plurality of individual aerosol generating portions. In any of the above embodiments, the aerosol generating layer includes a plurality of individual aerosol generating portions.

[0079] In any of the embodiments described above, the resistance heating element is one of a plurality of resistance heating elements.

[0080] In any of the embodiments described above, one of the individual aerosol generating sections is associated with a corresponding one of a plurality of resistance heating elements.

[0081] In any of the embodiments described above, the aerosol-generating layer includes at least one of dots, strips, and patches.

[0082] In any of the embodiments described above, the resistance heating element is a first heating element, the resistance heating layer forms a second resistance heating element, and each resistance heating element provides a conductive path for resistance heating of a portion of the aerosol generating material in order to generate an aerosol in each portion of the aerosol generating material.

[0083] In any of the embodiments described above, the resistance heating element is a first heating element, the resistance heating layer forms a second resistance heating element, and each resistance heating element provides a conductive path for resistance heating a portion of the aerosol generating material in order to generate an aerosol in each portion of the aerosol generating layer.

[0084] In any of the embodiments described above, the resistance heating layer forms an array of resistance heating elements, which includes at least a first resistance heating element and a second resistance heating element.

[0085] In any of the embodiments described above, each of the first type of electrical contact and the second type of electrical contact is configured to allow current to be supplied individually to each of the resistance heating elements.

[0086] In any of the above embodiments, the aerosol generating layer includes a film or gel layer containing an aerosol generating material.

[0087] In any of the above embodiments, the aerosol generator includes a plurality of first-kind electrical contacts, and each of the heating elements includes a separate first-kind electrical contact.

[0088] In any of the embodiments described above, the aerosol generator includes a plurality of second types of electrical contacts, and each of the resistance heating elements includes a separate second type of electrical contact.

[0089] In any of the above embodiments, the aerosol generator includes a single second type of electrical contact.

[0090] In any of the embodiments described above, a single second type of electrical contact is shared among each of the resistive heating elements.

[0091] In any of the above embodiments, the resistance heating element is formed by at least one of cutting the resistance heating layer, chemically etching the resistance heating layer, forming or pressing the resistance heating layer within the substrate, and printing the resistance heating layer.

[0092] In any of the above embodiments, the resistance heating layer is in the form of a foil.

[0093] According to one embodiment, an aerosol supply system is provided, comprising an article according to any of the above embodiments and an aerosol supply device configured to receive at least a portion of the article.

[0094] In any of the above embodiments, the aerosol supply device includes an electrical connector configured to be electrically connected to a first type of electrical contact and a second type of electrical contact.

[0095] In any of the above embodiments, the electrical connector includes device electrical contacts.

[0096] In any of the above embodiments, the device electrical contacts do not overlap with the flow path during use.

[0097] In any of the above embodiments, the device's electrical contacts overlap with the main body during use.

[0098] In any of the above embodiments, the device electrical contacts act on the main body during use.

[0099] In any of the above embodiments, when in use, the device electrical contacts act on a portion of the resistance heating layer that overlaps with the main body.

[0100] In any of the above embodiments, the flow path does not substantially overlap with the electrical connector during use.

[0101] In any of the above embodiments, the electrical connector does not apply a substantially force toward the flow path to the article during use.

[0102] According to one embodiment, an aerosol supply device is provided comprising a main body; a receptacle within the main body defining a chamber configured to receive at least a portion of an aerosol product; a conduit within the main body through which air can flow and which includes an air outlet communicating with the chamber; and a sealing member within the receptacle defining at least a portion of the conduit and configured to engage sealably with the aerosol product in the chamber.

[0103] A sealing member within a receptacle, configured to define at least a portion of a conduit and to engage in a sealable manner with the aerosol product in the chamber.

[0104] In any of the embodiments described above, the sealing member is configured to define an air outlet.

[0105] In any of the embodiments described above, the sealing member is configured to align with the article air inlet of the article.

[0106] In any of the embodiments described above, the sealing member is configured to cover and seal the air inlet of the article.

[0107] In any of the above embodiments, the sealing member is elastic.

[0108] In any of the above embodiments, the sealing member protrudes from the receptacle.

[0109] In any of the above embodiments, the sealing member is configured to bias the article and position it within the receptacle.

[0110] In any of the embodiments described above, the conduit is a first conduit, and the device comprises a second conduit through which air can flow inside the body, the second conduit including a second air outlet communicating with a chamber.

[0111] In any of the embodiments described above, the sealing member is a first sealing member, and the device includes a second sealing member within the receptacle, the second sealing member being configured to define at least a portion of the second conduit and to engage sealably with the aerosol product in the chamber.

[0112] In any of the above embodiments, the second sealing member is configured to form a second air outlet.

[0113] In any of the embodiments described above, the second sealing member is configured to align with a second article air inlet on the article.

[0114] In any of the embodiments described above, the second sealing member is configured to cover and seal the second article air inlet on the article.

[0115] In any of the embodiments described above, the first sealing member faces the second sealing member.

[0116] In any of the embodiments described above, the first and second sealing members are configured to grip a portion of the article between them.

[0117] In any of the embodiments described above, once an article is received by the device, the air outlet is configured to form a closed air path between the conduit and the article air inlet so that the article air inlet substantially receives only air from the air outlet when in use.

[0118] In any of the embodiments described above, the device comprises an electrical connector configured to electrically connect to a first type of exposed electrical contact area of ​​an article.

[0119] In any of the embodiments described above, the electrical connector is configured to electrically connect to a second type of exposed electrical contact area of ​​the article.

[0120] In any of the embodiments described above, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and width, where the length is greater than or equal to the width and the width is greater than the depth.

[0121] In any of the embodiments described above, the article defines at least one main surface, and the air inlet is defined on the main surface.

[0122] In any of the above embodiments, the aerosol supply device includes a sensor configured to determine changes in the airflow within the conduit.

[0123] In any of the above embodiments, the sensor is a microphone.

[0124] In any of the embodiments described above, the sensor is a puff detector.

[0125] According to one embodiment, an aerosol generator for an aerosol supply device is provided, comprising an aerosol generating material, a resistance heating layer including a resistance heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol, a first type of electrical contact, and a second type of electrical contact, wherein the resistance heating element is at least a portion of a conductive path between the first type of electrical contact and the second type of electrical contact.

[0126] 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.

[0127] According to one embodiment, an aerosol supply device is provided that is configured to receive an aerosol generator or article for any of the above-described aerosol supply devices.

[0128] According to one embodiment, an aerosol supply system is provided comprising an article containing an aerosol generating material and an aerosol supply device according to any of the above embodiments.

[0129] Next, various embodiments will be described as mere examples, with reference to the attached schematic diagram. [Brief explanation of the drawing]

[0130] [Figure 1] This is a schematic perspective view of an aerosol supply system. [Figure 2] Figure 1 is a schematic perspective view of an article containing aerosol-generating material for the aerosol supply system. [Figure 3] Figure 2 is a schematic perspective view of the first side of the aerosol generator of the article. [Figure 4] Figure 3 is a schematic perspective view of a portion of the second side of the aerosol generator. [Figure 5] Figure 1 is a schematic block diagram of an aerosol supply system, such as the one shown. [Figure 6] Figure 2 is a schematic partially exploded perspective view of the article, showing the aerosol generator reversed from its assembled orientation and separated from the other components. [Figure 7] Figure 3 is a schematic cross-sectional view of another aerosol generator, such as the aerosol generator shown. [Figure 8] Figure 3 is a schematic plan view of the heating element of the aerosol generator. [Figure 9] Figure 3 is a schematic plan view of the resistance heating layer of an aerosol generator having multiple heating elements. [Figure 10] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 11] This is a disassembled perspective view of the formed aerosol generator. [Figure 12] This is a schematic perspective view of the resistance heating layer of the aerosol generator that has been formed. [Figure 13] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 14] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 15] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 16] This is a schematic perspective view of the resistance heating layer of the aerosol generator that has been formed. [Figure 17] This is a schematic plan view of the heating element of the aerosol generator. [Figure 18] This is a schematic plan view of the heating element of the aerosol generator. [Figure 19] Figure 2 is a schematic perspective view of a portion of the aerosol generator of the item shown. [Figure 20] Figure 1 is a schematic perspective view of the device connector of the aerosol supply device in the aerosol supply system. [Figure 21] Figure 1 is a schematic side view of the aerosol generation system. [Figure 22] According to the method for forming an aerosol generator, such as the aerosol generator shown in Figure 3. [Figure 23] This shows 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] Figure 2 is a schematic cross-sectional plan view of the article. [Figure 27] This is a schematic cross-sectional plan view of another item. [Figure 28] This is a schematic cross-sectional plan view of another item. [Figure 29] This is a schematic cross-sectional plan view of another item. [Figure 30] Figure 29 is a schematic perspective view of the item. [Figure 31] Figure 29 is a schematic cross-sectional side view of another goods supply system including the goods. [Figure 32] This is a schematic cross-sectional side view of another goods supply system. [Modes for carrying out the invention]

[0131] As used herein, the term “delivery mechanism” is intended to encompass systems for delivering substances to a user, including non-combustible aerosol delivery systems that release compounds from aerosolizable materials without burning the materials, such as hybrid systems that generate aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosolizable materials, and articles comprising aerosolizable materials and configured for use in one of these non-combustible aerosol delivery systems.

[0132] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating constituent materials (or components thereof) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0133] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0134] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0135] 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.

[0136] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system 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.

[0137] 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.

[0138] 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.

[0139] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, a power supply.

[0140] 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 mouthpiece, a filter, and / or an aerosol modifier.

[0141] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, packaging material, a filter, a suction nozzle, and / or an aerosol modifier.

[0142] As used herein, “aerosol-generating material” (sometimes referred to herein as “aerosolizable material”) is a material that can generate an aerosol when heated, irradiated, or electrically charged in any other manner. The aerosol-generating material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0143] In some embodiments, the delivered substance includes an active substance (sometimes referred to herein as an active compound).

[0144] The aerosol-generating material may include one or more active substances and / or flavoring agents, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0145] 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 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.

[0146] 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 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.

[0147] 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.

[0148] The aerosol-generating film may be continuous. For example, the film may consist of a continuous sheet of material, or a continuous sheet of material.

[0149] 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.

[0150] In the embodiment, the aerosol-generating material comprises a plurality of aerosol-generating films. In the embodiment, the aerosol-generating film comprises a plurality of aerosol-generating film regions. Such plurality of aerosol-generating films and / or plurality of aerosol-generating film regions may have different properties, such as different compositions, thicknesses, densities, active substances and / or flavoring agents, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0151] 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.

[0152] The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent.

[0153] 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.

[0154] The aerosol-forming agent material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may contain one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0155] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0156] The material may be present on or within a support to form a substrate. The support may be, for example, paper, cardboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may contain these materials.

[0157] 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 the aerosol-generating material at the time of use and is heated to volatilize the aerosol-generating material, and optionally, other components at the time of use. The user may insert the article into or onto the aerosol supply device before the article is heated to generate an aerosol, after which the user inhales the aerosol.

[0158] 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.

[0159] Consumables are articles containing or consisting of aerosol-generating material, some or all of which are intended to be consumed by the user during use. 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 transfer component, an aerosol-generating area, a housing, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may include a conductor that can be heated by an electric current passing through it.

[0160] A non-combustible aerosol supply system may comprise a modular assembly that includes both a reusable aerosol supply device and replaceable aerosol products. In some implementations, the non-combustible aerosol supply device may include a power source and a controller (or control circuit). The power source may include, for example, a battery or rechargeable battery. In some implementations, the non-combustible aerosol supply device may also include an aerosol generating component. However, in other implementations, the aerosol product may include the aerosol generating component partially or entirely.

[0161] Figure 1 shows a schematic diagram of the aerosol supply system 100. The aerosol supply system 100 comprises an aerosol supply device 200 and an article 300 containing an aerosol generating material 302 (see Figure 3). In Figure 2, the article 300 is shown detached from the aerosol supply device 200. The aerosol generator 304 of the article 300 is shown in Figure 3 by a perspective view of the first side 306, and a perspective view of a portion of the second side 307 is shown in Figure 4.

[0162] Article 300 includes an aerosol generator 304. The aerosol generator 304 is configured to generate an aerosol from an aerosol-generating material 302 when the aerosol supply system 100 is in operation, as will be described in detail below.

[0163] The aerosol supply system 100 may be elongated and extend along its longitudinal axis. The aerosol supply system 100 has a proximal end 102 closest to the user (e.g., the user's mouth) when used by the user for inhaling the aerosol generated by the aerosol supply system 100, and a distal end 104 furthest from the user when used.

[0164] The proximal end may also be called the “mouthpiece end.” Thus, the aerosol supply system 100 defines a proximal direction that is directed toward the user during use. Furthermore, the aerosol supply system 100 similarly defines a distal direction that is directed away from the user during use. The terms “proximal” and “distal” applied to the features of system 100 are explained by referring to the relative positioning of such features relative to each other in the proximal-distal direction along the longitudinal axis.

[0165] 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 within the device chamber 206. A receptacle 208 defines the chamber 206. The receptacle 208 includes a receptacle base 210 and a receptacle periphery 212. The configuration of the receptacle 208 may vary depending on the configuration of article 300.

[0166] One or more user-operable control elements 224, such as buttons or switches, may be provided on the aerosol supply device 200 for use in operating the aerosol supply system 100. For example, a user may activate the system 100 by pressing a control element 224. One or more user-operable control elements may be omitted. In embodiments, the aerosol supply system 100 is operated by another user action, such as suction activated by a user drawing air through the system.

[0167] The aerosol supply device 200 has an opening 214 at its proximal end that leads into the device chamber 206. The opening 214 is located at one end and through 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 by another feature of the device 200 during use. In this configuration, the article 300 defines a mouthpiece 310 at its proximal end 308. In other embodiments, the device 200 defines the mouthpiece. The user places their mouth over the mouthpiece during use.

[0168] 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 into which it is inserted into the device, and this axis may be considered the insertion axis.

[0169] The aerosol supply device 200 includes a power source 220. The power source 220 may be a battery, for example, a rechargeable battery. The device 200 also includes a control circuit 222 which functions as a controller, comprising a processor and memory.

[0170] As will be discussed in detail below, the heating system 110 is configured to heat the aerosol-generating material 302 of article 300. Article 300 in the embodiment is a consumable and interchangeable with other articles 300. The heating system 110 comprises an aerosol generator 304. The heating system 110 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.

[0171] The aerosol generator 304 forms part of article 300. The aerosol generator 304 includes a heating component 312 configured to heat at least one of the aerosol-generating material 302, such as a film and a gel, in order to generate an aerosol. The aerosol-generating material may be called an aerosolizable material.

[0172] The heating component 312 is a resistance heating component. In the embodiment, the heating element or each heating element is a resistance heating element, as will be described in detail below. In such a configuration, the heating system 110 includes a resistance heating generator which includes components for heating the heating component 312 by a resistance heating process. In this case, a current is applied directly to the resistance heating element, and the resulting current flow within the heating element, which functions as a heating component, heats the heating element by Joule heating. The resistance heating element includes a resistance material configured to generate heat when a suitable current passes through it, and the heating component 312 includes electrical contacts for supplying current to the resistance material. The presence of the resistance heating component 312 enables a compact configuration. Resistance heating provides an efficient configuration.

[0173] In the use of the aerosol supply system 100, air is drawn into the air inlet 314 of the article 300, as schematically indicated by arrow 316. As shown in Figure 2, the air inlet 314 is located on the side wall of the article 300. The air inlet 314 is located between the suction end and the distal end of the article 300. The air inlet is located proximal to the distal end of the article 300. In embodiments, the air inlet 314 may have a different configuration, for example, at the distal end. The air inlet 314 is shown in rectangular cross-section. In embodiments, the air inlet 314 may have a cross-section of any shape, for example, square, circular, elliptical, cruciate, capsule-shaped, or any other suitable shape. The airflow to the air inlet 314 of the article 300 may be defined by at least one of the following: an air path through the device 200, an air path outside the device 200, and an air path between the device 200 and the article 300. The aerosol generated by the aerosol generator 304 exits the device at the aerosol outlet 318, as indicated by arrow 319. In some embodiments, the aerosol outlet 318 is located within the mouthpiece of the article 300 so that the aerosol is drawn directly from the article 300 to the user's mouth in the device 100. In some embodiments, the air outlet 318 may be located at or toward the mouthpiece end. The flow path of the article 300 will be described in further detail below.

[0174] In some exemplary embodiments, an aerosol supply system comprises two main components: a control section that forms reusable parts and a consumables section that forms replaceable or disposable parts, which may be called replaceable or disposable articles or cartridges. As described herein, the aerosol supply device 200 forms the control section, and the article 300 forms the consumables section. In the use of the aerosol generation system, the control section and the consumables may be releasably connected at an interface. The consumables may be removable and replaceable, for example, when the consumables are used up, and the control section may be reused with different consumables.

[0175] The illustrated aerosol supply system 100 is provided merely as an example and is highly schematic. Different aerosol generating devices and other devices may be used in exemplary implementations of the principles described herein. For example, in some exemplary embodiments, air is drawn in through an air inlet in a control section, passes through an interface, and exits through consumable parts.

[0176] 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.

[0177] The configuration of article 300 may vary. Article 300 includes a body 324. The body 324 is hollow. The body 324 defines a channel 326 through article 300 (see, for example, Figures 6 and 26-32). The channel 326 extends between an air inlet 314 and an aerosol outlet 318. The channel 326 is defined by an internal space within the article through which air and / or aerosols can flow. The channel 326 is defined within the body 324. The body 324 may define a channel 326 of any suitable shape. For example, the channel 326 may be at least one of spiral, angled, and tapered. An aerosol generator or each aerosol generator 304 borders the channel 326. The aerosol generating material 302 is exposed in the channel 326. The aerosol generating material 302 is exposed in the internal space. The internal space in the embodiment includes two or more chambers.

[0178] The air inlet 314 includes an opening 315. The opening 315 is formed in the body 324. The opening 315 is formed in the longitudinal wall of the body 324. The opening is spaced apart from the distal end of the body 324. In embodiments, the opening is formed in another component of the article 300, such as the aerosol generator 304 or another wall feature. The aerosol outlet 318 includes an outlet opening 317. The outlet opening 317 is formed in the body 324. In embodiments, the outlet opening 317 is formed in another component of the article 300, such as the aerosol generator 304 or another wall feature.

[0179] As shown in Figure 6, article 300 includes two aerosol generators 304 that form an aerosol generator configuration. The number of aerosol generators 304 may vary. Each aerosol generator 304 contains an aerosol generating material 302. The aerosol generating material 302 is exposed to a channel 326. In embodiments, article 300 includes a single aerosol generator 304. One of the aerosol generators 304 is described in detail, and such details are applicable to one or more further aerosol generators 304 in embodiments.

[0180] The aerosol generator or each aerosol generator 304 and the main body 324 are formed in a stacked configuration. In embodiments, other arrangements such as a tubular arrangement of articles are envisioned. In such a tubular arrangement, the aerosol generator 304 defines a tubular configuration. The tubular shape may include a circular cross-section, an elliptical cross-section, and other polygonal shapes.

[0181] In this embodiment, as shown in the figure, article 300 has a flat configuration. That is, in this case, the exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and width, where the length is greater than or equal to the width and the width is greater than the depth. Other configurations are also conceivable.

[0182] Figure 6 is an exploded perspective view of article 300, in which the aerosol generator 304 is shown inverted from its assembled orientation and spaced apart from the other components. Article 300 includes a first aerosol generator 302, a body 324, and a second aerosol generator 304. The body 324 separates the first and second aerosol generators 304. The first and second aerosol generators 304 enclose an internal space defined by the body 324, allowing air and / or aerosols to flow along the internal space. The aerosol-generating materials 302 of the first and second aerosol generators 304 are exposed to the internal space facing each other. When assembled, the first and second aerosol generators 304 sandwich the body 324. In the embodiment of Figure 6, at least the first and second aerosol generators 304 and the body have equal planar areas. In the embodiment, one or more of the first and second aerosol generators 304 and the body 324 have a greater length and / or width. In the embodiment, one of the first and second aerosol generators 304 is replaced by a blank panel. The body 324 includes a body layer. The body may include multiple body layers. The body layers may be formed by stacking and arranged to define features of the article 300, such as an air inlet 314 and an aerosol outlet 318.

[0183] The wrap surrounds the article 300 and forms part of the article 300. The wrap may include a sheet. The wrap functions as a fixing sleeve. The aerosol generator or each aerosol generator 304 protrudes from the wrap at its distal end. The exposed electrical contact area 323 of the heater contact 322 is exposed at its distal end, as shown in Figure 2, for example. Other configurations are conceivable, for example, at least one exposed electrical contact area 323 may be additionally or alternatively defined on the main surface of the article defined by the aerosol generator 304, along the short longitudinal surface or edge of the article 300.

[0184] The aerosol generator 304 is schematically shown in cross-section in Figure 7. The aerosol generator 304 is an implementation of the aerosol generator 304 of the aerosol supply system 100 described above.

[0185] The aerosol generator 304 includes an aerosol generating layer 330, also known as an aerosolizable layer. The aerosol generating layer 330 includes an aerosol generating material 302. The aerosol generator 304 includes a resistance heating layer 340. In embodiments, the resistance heating layer 340 is formed as a conductive layer. The aerosol generating layer 330 is located on the resistance heating layer 340. The aerosol generating layer 330 is in direct contact with the resistance heating layer 340. In embodiments, the aerosol generating layer 330 is in indirect contact with the resistance heating layer 340. In embodiments, the resistance heating layer 340 may include a coating. As will be described in detail below, the resistance heating layer 340 includes a plurality of resistance heating elements 342, for example, as shown in Figures 8 and 9. Each resistance heating element or each resistance heating element 342 forms at least a portion of a conductive path between a pair of electrical contacts 322. Each resistance heating element or each resistance heating element 342 provides a conductive path for resistance heating of 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.

[0186] 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.

[0187] The aerosol generator 304 includes a support 350. In this embodiment, the support 350 includes paper or card material. The support 350 provides structural support for the aerosol generator 304. The resistance heating layer 340 is located on the support 350. The support 350 is configured as a support layer. As shown in Figure 7, in the aerosol generator 304, the resistance heating layer 340 is sandwiched between the support 350 and the aerosol generation layer 330.

[0188] The support 350 is electrically insulating. The resistance heating layer 340 and the support layer 350 define the substrate 352. The substrate 352 supports the aerosol generating layer 330.

[0189] Article 300 may include a laminate 354 comprising a resistance heating layer 340 and a support layer 350. In embodiments, the laminate 354 includes an aerosol generating layer 330. The aerosol generating layer 330 may be formed as a continuous structure or from individual parts. The individual parts may include one or more of the following shapes: dots, strips, helices, or other shapes.

[0190] In the embodiment, the aerosol generating layer 330 includes an aerosol generating film. In the embodiment, the aerosol generating layer 330 includes a plurality of aerosol generating films. In the embodiment, the aerosol generating film includes a plurality of aerosol generating film regions. Such plurality of aerosol generating films and / or plurality of aerosol generating film regions may have different properties, such as different compositions, thicknesses, densities, active substances and / or flavoring agents, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0191] One or more of the aerosol generation layer 330, the resistance heating layer 340, and the support layer 350 may include further layers. For example, the support layer 350 may include a backing layer or an intermediate layer. The support layer 350 is omitted in this embodiment.

[0192] Figure 8 shows one of the resistance heating elements 342. The resistance heating layer 340 includes a plurality of resistance heating elements 342. In this embodiment, the resistance heating layer 340 includes a single resistance heating element 342.

[0193] Multiple heating elements 342 may be formed in an array 344 as shown in Figure 9. Other configurations are also possible.

[0194] 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 spiral. The configuration of the resistive heating path may vary. The electrical resistance of the heating element 342 may depend on the properties of the resistive heating path in the conductive layer, such as the length, width, thickness, and arrangement of the path.

[0195] 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.

[0196] The meandering or winding nature of the path of the resistive heating element 342 is such that the electrical resistance of the path increases compared to a straight path between the first and second types of electrical contacts.

[0197] 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.

[0198] 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.

[0199] As will be discussed in detail below, the conductive path of the resistive heating element 342 in the embodiment is created by defining at least one electrically insulating barrier 346 within the resistive heating layer 340. In the embodiment, the electrically insulating barrier 346 is formed by cutting an electrically insulating barrier limiting portion (i.e., an electrically insulating portion), such as a gap, channel, or slot, into a sheet formed of a conductive material to form the resistive heating layer 340. In the embodiment, the resistive heating layer 340 is pre-formed to define the resistive heating element or each resistive heating element 342 and then applied to the support 350. In the embodiment, the resistive heating layer 340 is applied to the support 350 and then the resistive heating element or each resistive heating element 342 is defined within the resistive heating layer 340. The resistive heating element or each resistive heating element 342 defining the resistive heating layer 340 may be a printed heater. The insulating barrier may be a void. In the embodiment, the insulating barrier is, for example, a filled void filled with an insulating material. A barrier defines a barrier against electrical conduction across it.

[0200] The resistance heating elements defining the resistance heating layer 340, or each resistance heating element 342, may be formed by a cutting operation. The cutting operation may include die cutting. The resistance heating elements may be formed by an operation applied only to the resistance heating layer. In the embodiment, the resistance heating elements may be formed by an operation applied to both the resistance heating layer and the support layer, for example, by an operation that cuts the resistance heating layer and the support layer.

[0201] At least one electrical insulating barrier 346 defines first and second types of electrical tracks 361, 366.

[0202] In some embodiments, the tracks of the resistive heating element or each resistive heating element 342 have a width of 0.5 mm to 1 mm (two exemplary prototypes have widths of 0.93 mm and 0.72 mm, respectively), and a gap between tracks of less than approximately 0.25 mm (the same two exemplary prototypes have gaps of 0.2 mm and 0.05 mm, respectively). The resistive heating element or each resistive heating element 342 may have overall dimensions of approximately 10 mm × 10 mm. Other dimensions are possible in other exemplary embodiments. By forming resistive heating elements or each resistive heating element 342 of these dimensions from aluminum foil with a thickness of 0.006 mm and an electrical resistivity of 2 to 6 μOhm cm, the resistance of the path is calculated to be approximately 1 Ohm. In one exemplary embodiment, the resistance was measured at 0.83 to 1.31 Ohm.

[0203] As shown in Figure 9, the resistance heating layer 340 may be formed on a plurality of resistance heating elements generally indicated by reference numbers 342a, 342b, 242c, 342d, and 342e. Each of the resistance heating elements 342a to 342e extends from each of the first type of electrical contacts generally indicated by reference numbers 360a, 360b, 360c, 360d, and 360e to a single second type of electrical contact 365. The number of electrical contacts may vary. Thus, each resistance heating element 342a to 342e extends between individual first type electrical contacts and a common second type of electrical contact.

[0204] Each of the resistance heating elements 342a to 342e provides a conductive path for resistance heating a portion of the aerosol generating material 302 in order to generate an aerosol in each part of the aerosol generator 304.

[0205] The distinct first types of electrical contacts 360a to 360e allow current to be supplied individually to each of the multiple resistive heating elements 342a to 342e. This allows for control of heating of different zones of the aerosol generation layer 330. For example, the aerosol generator may have five aerosol generation zones. The resistive heating layer 340 allows each of these zones to be operated separately. Thus, for example, five aerosol aspirates may be produced from a single consumable incorporating a single aerosol generator 304, or ten aerosol aspirates may be produced from a single consumable incorporating two aerosol generators 304.

[0206] In an exemplary resistance heating layer 340, a plurality of first-type electrical contacts 360a to 360e, e.g., positive electrical connections, and a single second-type electrical contact 365, e.g., a negative electrical connection, are provided. This is not essential for all implementations. For example, a plurality of second-type contacts may be provided. In the embodiment, each resistance heating element 342a to 342e includes a corresponding first-type electrical contact 360 and a corresponding second-type electrical contact 365.

[0207] In the embodiment of the resistive heating layer 340 shown in Figure 9, the first type of electrical contacts 360a to 360e are located on the first edge 363 of the resistive heating layer 340, and the second type of electrical contacts 365 are located on the second edge 368 of the resistive heating layer 340. This allows for convenient power connection, but of course, many other configurations are possible, some of which will be discussed further below.

[0208] As shown in Figure 2, article 300 will be described in more detail with particular reference to the flow path and the first type of exposed electrical contact area 362 and the second type of exposed electrical contact area 367 (see Figure 4).

[0209] The flow path is configured so as not to substantially overlap with the exposed electrical contact areas of electrical contact 322 (hereinafter referred to as exposed electrical contact areas 362 and 367). Each of the exposed electrical contact areas 362 and 367, which are configured to contact the device contacts of the device connector, does not substantially map to any portion of the flow path. It should be understood that the flow path also includes an air inlet 314 and an air outlet 318. In this embodiment, such lack of overlap is further achieved by positioning the air inlet 314 on the longitudinal side of the article, longitudinally spaced apart from the exposed electrical contact areas 362 and 367, which are positioned toward the distal end of the article 300. Such a configuration is schematically shown in Figure 26. The cross-hatched area 380 in Figure 26 represents the exposed electrical contact area of ​​electrical contact 322. The flow path 326 is offset from the exposed electrical contact area of ​​electrical contact 322. The exposed electrical contact area of ​​electrical contact 322 does not extend into the internal space of the article through which air and / or aerosols can flow. The internal space is bounded by the main body 324. The main body defines the wall 327 of the article. The exposed electrical contact areas 362, 367 of the electrical contacts 322 overlap with the wall 327 of the article. The main body wall 327 supports the exposed electrical contact areas 362, 367 of the electrical contacts 322.

[0210] The main body 324 includes a main body layer 325, and the main body layer includes a portion of the stack of main body layers that includes the main body. In this case, the air inlet 314 is defined by an area where the number of main body layers is reduced. That is, the air inlet 314 is formed by omitting a certain region of the main body layer.

[0211] Figure 27 shows another embodiment of article 300 in which an air inlet 314 is formed in the aerosol generator 304, while remaining substantially separate from the exposed electrical contact areas 362, 367. The cross-hatched area 380 in Figure 27 represents the exposed electrical contact area of ​​electrical contact 322. The air inlet 314 may be formed in the support layer 350 or substrate 352 and longitudinally offset from the exposed electrical contact areas 362, 367, as indicated by being offset from the cross-hatched area 380. In some embodiments, there may be a second air inlet positioned in the article to increase the airflow through the article. The second air inlet may be positioned according to any of the embodiments described above. The second air inlet may or may not substantially overlap the flow path.

[0212] In this embodiment, the air inlet 314 is located downstream of each of the exposed electrical contact areas 362 and 367. Downstream is understood to mean that the air inlet 314 is located between the intake end and each of the exposed electrical contact areas 362 and 367. Furthermore, in some embodiments, each of the exposed electrical contact areas 362 and 367 may be located at the distal end or spaced apart along the longitudinal edge of the article 300. In this embodiment, each of the exposed electrical contact areas 362 and 367 is supported by the body 324. However, in some embodiments, neither of the exposed electrical contact areas 362 and 367 may be supported by the body 324, or only one of them may be supported.

[0213] If there is an overlap between the air passage and the exposed contact area, it can be assumed that the force applied by the device connector electrical contact 232 toward and / or to the exposed contact area acts at least partially on the flow path 326. For example, a force may act on any part of the article defining the air passage and / or part of the air inlet 314 and / or air outlet 318. This may then deform any or all of the features forming the flow path 326. Deformation should be understood as the flow path 326 being manipulated in some way to change its shape and / or the airflow characteristics through it. For example, a constricted area in the flow path 326 may be induced. Such deformation is undesirable because the flow characteristics through article 300 may differ from those of an undeformed flow path 326. Therefore, by eliminating substantial overlap between the flow path and each of the exposed electrical contact areas 362, 367, air and / or aerosols can flow more uniformly and consistently in and through the air passage. Importantly, air and / or aerosols flow through Article 300 for its intended use.

[0214] Figure 28 shows a further embodiment of article 300. In this embodiment, the flow path can be offset laterally from the exposed electrical contact areas 362, 367 so that the exposed electrical contact areas 362, 367 and the flow path do not substantially overlap. The cross-hatched area 380 in Figure 28 represents the exposed electrical contact area of ​​electrical contact 322. For example, the exposed electrical contact areas 362, 367 may be arranged continuously in the longitudinal direction, and the flow path may be arranged substantially parallel to the exposed electrical contact areas 362, 367 and the longitudinal axis. It can be assumed that the exposed electrical contact areas 362, 367 may be arranged such that they do not align laterally and / or longitudinally, but remain substantially unoverlapping with the flow path. This arrangement provides an air inlet 314 at the distal end of article 300 and an air outlet 301 at the proximal end. Such an arrangement may be desirable so that the airflow through the article remains substantially layered. By providing a substantially laminar flow through article 300, the dispersion and / or delivery of aerosols to the user can be made more uniform. Furthermore, the user may find that drawing in laminar flow through article 300 requires less effort than drawing in turbulent flow. Naturally, the air inlet may be formed through the aerosol generator 304, for example, via a support layer 350 or a substrate 352.

[0215] Figures 29 and 30 show further embodiments of article 300. Figure 30 shows a perspective view of the article of Figure 29. In this embodiment, the exposed electrical contact areas 362, 367 can be offset from the body 324 so that the exposed electrical contact areas 362, 367 and the flow path 326 do not substantially overlap. In this embodiment, the exposed electrical contact areas 362, 367 are located on a protruding panel 390 that extends away from the body 324. The cross-hatched area 380 in Figure 29 represents the exposed electrical contact area of ​​electrical contact 322. As can be seen in Figures 29 and 30, the air inlet 316, flow path 326 and air outlet 318 all do not substantially overlap the exposed electrical contact area of ​​electrical contact 322. Figures 29 and 30 are described in more detail below.

[0216] Figure 10 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, generally referred to as reference number 400, according to an exemplary embodiment.

[0217] 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. When in use, the heating elements or each heating element may be used to provide a conductive path for resistively heating a portion of an aerosol-generating material to generate an aerosol. The formation of the resistive heating elements or each resistive heating element may be performed before or after applying the resistive heating layer on a support, if a support is present. The resistive heating layer may be bonded to the support, or mounted or formed on the support in a different configuration.

[0218] In operation 404, the formed resistance heating layer is positioned in contact with the aerosol generating layer, which incorporates an aerosol generating material. The aerosol generator 304 described above may be generated using algorithm 400.

[0219] Figure 11 shows an aerosol generator 304 formed according to an embodiment. The aerosol generating material 302 is formed on the resistance heating layer 340, for example by spraying, painting, dispensing, or by depositing the aerosol generating material in some other way. In an exemplary implementation of operation 404, the aerosol generating layer 330 is disposed on the resistance heating layer 340 as indicated by arrow 406.

[0220] Figure 12 shows a resistance heating layer 340 formed according to an exemplary embodiment. The resistance heating layer 340 is in the process of being cut using a laser cutter 408. Cutting the resistance heating layer 340 can be used to form the paths for the heating elements described herein. The use of a laser cutter 408 (or any other cutting process) is not the only way in which the resistance heating layer 340 described herein can be produced. Several exemplary methods are described below.

[0221] Figure 13 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, which is generally referred to as reference no. 410. The method or algorithm 410 begins with operation 412, in which a resistance heating layer is provided. In operation 414, one or more resistance heating elements are formed within the resistance heating layer by chemical etching of the resistance heating layer. Operations 412 and 414 are exemplary implementations of operation 402 of method 400 described above. An aerosol generating material is then placed on the resistance heating layer, thereby implementing operation 404 described above.

[0222] Figure 14 is a flowchart showing part of a method or algorithm for forming an aerosol generator 304, which is generally referred to as reference no. 418. The method or algorithm 418 begins with operation 420, in which one or more heating elements are formed by printing a resistance heating layer, at least partially. Thus, operation 420 is an exemplary implementation of operation 402 of algorithm 400 described above. The aerosol generating material is then placed on the resistance heating layer, thereby implementing operation 404 described above.

[0223] The cutting, etching, and printing methods described above are provided as examples, and other additional or alternative methods are also possible. For example, a so-called “hot foil” method can be used, in which the heating element is fabricated from a resistance heating layer and then assembled / bonded onto a support. Even further techniques such as die cutting can also be used. Furthermore, two or more techniques can be combined (for example, conductivity can be added to the connection trace by adding more conductive materials such as additional foil, printing material, etc.). Those skilled in the art will recognize many further techniques or combinations of techniques that can be used in the implementation forms of the principles described herein.

[0224] Figure 15 is a flowchart illustrating an exemplary embodiment of an operating method or algorithm, collectively referred to as reference numeral 424. The method or algorithm 424 may be implemented, for example, using one of the aerosol generators described herein. The method or algorithm 424 is initiated when a command to activate heating is received in an instance of operation 426. In response to the command to activate heating, a determination is made as to whether a heating element is available (operation 428). Multiple heating elements may be provided, as discussed above. Operation 428 may also involve determining which heating element has been used and / or whether the corresponding available aerosol-generating material has been exhausted.

[0225] If heating elements are available, the algorithm proceeds to operation 430, where the available heating elements are used. As discussed 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 in operation 432. If, in operation 428, it is determined that there are no available heating elements because, for example, all heating elements have been used, the algorithm terminates in operation 432. This may mean that the consumable parts used to implement algorithm 424 need to be replaced.

[0226] Figure 16 shows a resistance heating layer 340 formed according to an embodiment. The resistance heating layer 340 is cut using a laser cutter 408, but other methods such as chemical etching or printing may also be used, as discussed above. The cuts in the conductive layer 340 form heating elements as described herein.

[0227] In the embodiment shown in Figure 16, the path to be cut is a linear path that extends along the length of the conductive layer 120.

[0228] Figure 17 shows another embodiment of the resistance heating layer 340. The resistance heating layer 340 can be formed using the laser cutter 408 described above, or some similar device or other method. The resistance heating layer 340 includes a plurality of resistance heating elements 342, each resistance heating element 342 being a linear heating element with a conductive path extending along the length of the resistance heating layer 340. Each resistance heating element 342 extends from one of the first type of electrical contacts 360, e.g., a positive electrical connection, to one of the second type of electrical contacts 365, e.g., a negative electrical contact. In such embodiments, both types of electrical contacts are located at the same end of the resistance heating layer 340 and are adjacent to each other. In configurations where there is no common second type of electrical contact, as in some other embodiments, each heating element instead has separate first and second type electrical contacts.

[0229] Figure 18 shows another embodiment of the resistance heating layer 340. The resistance heating layer 340 can be formed using the laser cutter 408 described above, or some similar device or other method. The resistance heating layer 340 includes a plurality of heating elements 342, each heating element 342 being a linear heating element with a conductive path extending along the length of the resistance heating layer 340. Each resistance heating element 342 extends from one of a first type of electrical contact 360, e.g., a positive electrical connection, to a second type of electrical contact 365, e.g., a negative electrical contact. In such embodiments, different types of electrical connections are provided at both ends of the resistance heating layer 340, and a common second type of electrical contact is provided. Although a linear path is provided, an increase in electrical resistance may be provided by providing a notched path that functions as a spiral path. Note that the paths of any other embodiments described herein can also be notched.

[0230] Figure 19 shows the distal end of article 300. As shown, the body 324 includes a plurality of body layers 325. The body layers 325 are arranged in a laminate of body layers 325. The body layers 325 form a laminate. In this embodiment, the body layers 325 are card layers. Other suitable materials may be used. The body layers 325 are configured to define the features of article 300. In this embodiment, at least one body layer includes a gap that defines an air inlet 315. The gap defines an opening 314.

[0231] 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 providing positive electrical connections to, for example, each of a plurality of heating elements 342, and a single second type of electrical contact 365 providing a common negative electrical connection to, for example, the plurality of heating elements 342. The first type of electrical contact 360 and the second type of electrical contact 365, i.e., the heater contact 322, together form at least a portion of the article electrical contact configuration 320 of the aerosol generator 304.

[0232] The resistive heating element 342 is located inside the resistive heating layer 340. The inside defines the first side 306 of the aerosol generator 304, as shown in Figure 3. The heater contact 322 is located on the second side 307 of the resistive heating layer 340. The second side 307 defines the outside of the aerosol generator 304. The heater contact 322 is exposed so as to be able to contact the device electrical connector 230. The heater contact 322 is on the opposite side of the resistive heating layer 340 from the resistive heating element 342. Other configurations are also possible.

[0233] The support layer 350 is located between the inner portion and the outer portion of the resistance heating layer 340.

[0234] A fold 370 is formed in the resistance heating layer 340. The fold 370 defines the heater contact 322. As shown in Figures 2-4 and Figure 19, the fold 370 extends perpendicular to the longitudinal axis of the aerosol generator 304. The fold 370 defines the flap 372. The heater contact 322 is located on the flap 372. The flap defines the contact panel. The remaining blank portion defines the main panel.

[0235] In embodiments having a support layer 350, the support layer 350 is folded in the embodiment. The base material 352 is folded at the fold 370. In the embodiment, the support layer 350 is terminated at the fold. In the embodiment, the fold 370 extends parallel to the longitudinal axis of the aerosol generator 304.

[0236] The folded portion of the resistance heating layer 340 is fixed in the folded position. In this embodiment, this folded portion is bonded, for example, by a joint. Other fastening means are also anticipated.

[0237] The fold 370 defines a first type of exposed contact area 362. The fold 370 defines a second type of exposed contact area 367. Electrical tracks 361 and 366 are electrically connected across the fold 370. The heater contacts 322 of the first type of electrical track 361 and the second type of electrical track 366 are defined on the second side of the resistance heating layer 340. Parts of the first type of electrical track 361 and the second type of electrical track 366 extend to the first side of the resistance heating layer 340. In embodiments, the resistance heating element extends from the fold 370. Other configurations are also conceivable.

[0238] Device 200 comprises multiple connector electrical contacts 232 of an electrical connector 230. The configuration of the device connector 230 depends on the configuration of the heater contacts 322 of the aerosol generator 304. In embodiments such as the aerosol generator shown in Figure 19, the aerosol generator 300 includes multiple heater contacts 322, including one of a plurality of first type heater contacts 360 and a plurality of second type heater contacts 365. Article 300 includes another set of heater contacts 322 on the opposite side of article 300 corresponding to the second aerosol generator 304.

[0239] 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.

[0240] 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 comprises a first connector 230a and a second connector 230b.

[0241] Connectors 230a and 230b allow the aerosol supply device 200 to supply a regulated or controlled voltage and / or current to various first-type heater contacts 360 and second-type heater contacts 365 of the aerosol generator 304 when the article 300 is inserted into the aerosol supply device 200. The aerosol supply device 200 may include connector components configured to supply power to connectors 230a and 230b. The aerosol supply device 200 may operate, for example, in the manner described above.

[0242] Figure 22 is a flowchart showing a method or algorithm for forming an aerosol generator 304, generally referred to as reference number 440, according to an exemplary embodiment.

[0243] 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 at least a portion of the aerosolizable material to generate an aerosol. Exemplary heating elements that may be formed in operation 442 are described elsewhere herein.

[0244] In operation 442, the aerosol-generating material is applied and / or formed on the resistance heating layer.

[0245] Operations 442 and 444 of method or algorithm 440 are the same as (or may be identical to) operations 402 and 404 of method or algorithm 400 described above.

[0246] In operation 446, at least one first type of electrical contact is provided on the resistance heating layer. The method of formation may be any of the methods described above. In operation 448, at least one second type of electrical contact is provided on the resistance heating layer. The method of formation may be any of the methods described above.

[0247] In the embodiment, the first and second types of electrical contacts are formed along or near a single edge of the resistance heating layer. In the embodiment, the first and second types of electrical contacts are formed along or near different edges of the resistance heating layer.

[0248] In the embodiment, a first type of electrical contact (e.g., a positive 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 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.

[0249] In operation 450, the resistance heating layer is folded. In the embodiment, the support layer is folded together with the resistance heating layer. In the embodiment, the resistance heating layer is folded such that first and second types of electrical contacts are provided adjacent to each other, as will be discussed in detail below.

[0250] Figures 23 to 25 show embodiments of the aerosol generator 304 formed according to algorithm 440.

[0251] 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 the blank for forming the aerosol generator 304. The blank in the embodiment defines the fold lines that are made during the formation of the aerosol generator. The aerosol generator 304 blank includes the resistance heating layer 340 and the support layer 350. The resistance heating layer 340 and the support layer 350 define the panel defined by the fold lines.

[0252] As shown in Figure 23, the resistance heating layer 340 is formed on multiple heating elements 192, but the number may vary, or there may be only one. Multiple first type electrical contacts 360 (e.g., positive electrical contacts) are provided along the first edge of the conductive layer (one contact is shown for each heating element). A single second type electrical contact 365 is provided along the second edge of the resistance heating layer 340. In this embodiment, the contacts are spaced apart from the edge. As discussed above, each of the multiple heating elements extends from the first type electrical contact to the second type electrical contact.

[0253] The cuts made by the laser cutter 408 in the resistance heating layer 340 form heating elements or paths for each heating element 342. As discussed above, laser forming or any other cutting process is not the only way to produce the resistance heating layer 340 described above. Some exemplary alternative methods include chemical etching and printing.

[0254] As shown in Figure 24, the aerosol generating layer 200 is provided on the resistance heating layer 340. Next, the blank is folded as indicated by the arrows in Figure 24. In this embodiment, the folds are formed parallel to the longitudinal direction of the aerosol generator 304. Two folds are formed. A first panel 375 containing a heating element 342 is defined. A second panel 376 containing a plurality of first type electrical contacts 360 is formed. A third panel 377 containing second type electrical contacts 365 is formed. The aerosol generating layer 330 is on the first panel 375. Figure 25 shows the folded aerosol generator 304.

[0255] Figure 30 is a simplified embodiment of the article 300 described above with reference to Figure 29. In this embodiment, the article 300 includes an aerosol generator 304, which may be any of the aerosol generators described above, and a body 324 that partially defines a channel 326 through which an aerosol can flow within the article 300. The article 300 includes a first type of electrical contact 360 and a second type of electrical contact 365, and the resistance heating element is at least a portion of the conductive path between the first type of electrical contact and the second type of electrical contact.

[0256] In this embodiment, the first type of electrical contact 360 and the second type of electrical contact 365 are offset from the body 324. As shown in Figure 30, this is achieved by an article 300 having a protruding panel 390, which acts as a protruding member to protrude from the body 324 with the first type of electrical contact 360 and the second type of electrical contact 365 located on the protruding panel 390. In this embodiment, only one or a limited number of the first type of electrical contact 360 and the second type of electrical contact 365 are located on the protruding panel 390.

[0257] In this embodiment, the support 350 and the resistive layer 340, which together define the substrate 352, extend across the main body 324. In this case, the substrate 352 defines the protruding panel 390. However, in some embodiments, the protruding panel 390 may be a separate layer from the support 350. The protruding panel 390 is shown to protrude from the longitudinal end of the main body. That is, the protruding panel 390 further extends the article 300 beyond the main body 324. In some embodiments, the protruding panel may protrude from the longitudinal side of the main body. That is, the protruding panel further extends the overall width of the article 300 beyond the main body 324.

[0258] As shown in Figure 30, both the first type of electrical contact 360 and the second type of electrical contact 365 are positioned on the protruding panel, thereby offset from the body 324. The first type of electrical contact and the second type of electrical contact are shown on the outside of the protruding panel. The outside of the protruding panel 390 is the side facing outward from the body 324. However, the first type of electrical contact and the second type of electrical contact may also be on the inside of the protruding panel. The inside of the protruding panel 390 is the side opposite to the outside of the protruding panel 390. In the embodiment, the first type of electrical contact and the second type of electrical contact may be on different sides of the protruding panel. Only one of the electrical contacts needs to be on the protruding panel. One of the first type of electrical contact and the second type of electrical contact may substantially overlap with the body.

[0259] In this embodiment, the air inlet 314 is located at the distal end of the article 300. In this embodiment, the air inlet 314 is aligned with the longitudinal axis and the center. In embodiments, the air inlet 314 may have a different configuration, for example, being on the side. In some embodiments, the air inlet 314 may be formed through the aerosol generator 304, as described above with respect to other embodiments of the article 300. The air inlet 314 is shown in rectangular cross-section. The air inlet 314 may have a cross-section of any shape, for example, square, circular, elliptical, cruciate, capsule-shaped, or any other suitable shape.

[0260] The airflow to the air inlet 314 of article 300 may be defined by at least one of the following: an air path through device 200, an air path outside device 200, and an air path between device 200 and article 300. The aerosol generated by the aerosol generator 304 exits the device at the aerosol outlet 318. In one embodiment, the aerosol outlet 318 is located within the mouthpiece of article 300 so that the aerosol is drawn directly from article 300 into the user's mouth at device 200.

[0261] In some embodiments, the air outlet 318 may be located at or toward the end of the intake port. In use of the aerosol supply system 100, air is drawn into the air inlet 314 of the article 300. As shown in Figure 30, the protruding panel 390 is offset from the air inlet 316, thereby allowing the first type of electrical contacts 360 and the second type of electrical contacts 365 to not substantially overlap with the body 324, and in particular, not substantially overlap with the air inlet 316. In this embodiment, the protruding panel 390 protrudes away from the air inlet 316 to extend the article 300 longitudinally. In some embodiments, the protruding panel 390 protrudes away from the air inlet 316 to protrude laterally, that is, to increase the lateral width of the article 300.

[0262] During use, the device connector electrical contacts 232 may apply force to the first and second types of electrical contacts 360, 365. While this force may be beneficial for coupling the device to the article, such force may be undesirable if directed towards and acting upon any part of the body 324 and / or article that defines a flow path, for example, when directed towards the air inlet 314. For example, a force applied to the body 324 by the device connector electrical contacts 232, particularly toward the air inlet 314, may cause deformation, such as compression, of the body 324 and / or the air inlet 314.

[0263] Next, this may result in any or all of the features forming the channel 326 being deformed. Deformation should be understood as the channel 326 being manipulated in some way to change its shape and / or the airflow characteristics through it. For example, the channel 326 may be deformed to introduce constricted regions. Such deformation is undesirable because the flow characteristics through article 300 may differ from those of an undeformed channel 326. Therefore, by avoiding substantial overlap between the channel and the exposed electrical contact regions 362, 367, air and / or aerosols can flow more uniformly and consistently within and through the air passages. Air and / or aerosols flow through article 300 for its intended use.

[0264] Such compression of the air inlet 314 may reduce the amount of air that can be drawn into the article 300 in a single inhale, and / or may require the user to inhale more deeply to draw in the same amount of air compared to an article with an uncompressed body and / or air inlet, and may therefore be particularly undesirable. This may adversely affect the effectiveness of the article 300.

[0265] By offsetting at least one of the first type of electrical contact 360 and the second type of electrical contact 365 from the body, the force provided by the device connector electrical contact 232 does not act substantially on the body 324 and does not act on the air inlet 314. Furthermore, this arrangement allows the central air inlet to exist through the body at the distal end without the electrical connector electrical contact 232 compressing the body 324 and / or the air inlet 314. The central air inlet 314 at the distal end of the article 300 may be desirable so that the airflow through the article remains substantially laminar, especially when the air outlet 318 is located in the center of the proximal end of the article. By providing a substantially laminar flow through the article 300, the dispersion and / or delivery of aerosols to the user can be made more uniform. Furthermore, the user may find that it takes less effort to draw in laminar flow through the article 300 than turbulent flow. Naturally, the air inlet may be formed through the aerosol generator 304, for example, via a support layer 350 or a substrate 352.

[0266] Embodiments of article 300 shown in Figures 2 and 10 may form part of an aerosol supply system. The system further comprises an aerosol supply device 200, as shown in Figure 1, configured to receive at least a portion of article 300. As described above, the aerosol supply device 200 comprises an electrical connector 230 configured to electrically connect to a first type of electrical contact and a second type of electrical contact. The electrical connector 230 includes device electrical contacts 232 for contacting the first and second types of electrical contacts and thereby supplying power from the device to the article.

[0267] In some embodiments, device electrical connectors are positioned such that, during use, the electrical connectors, particularly the electrical connector contacts, do not overlap with the flow path. That is, they apply force directly to the first and / or second type of electrical contacts, and the force is offset from the flow path through the article. In particular, the device electrical connector contacts do not apply force substantially toward the flow path. Furthermore, to support the electrical connector contacts during use, the electrical connector contacts, if present, may be positioned to overlap or overlay with the body. In this way, the electrical connector contacts exert force toward the body rather than the flow path, thereby ensuring that the force applied by the electrical connector contacts does not result in deformation of the flow path.

[0268] It can be assumed that components of an electrical connector other than the electrical connector contacts may come into contact with an article and therefore act upon it. In some embodiments, there may be means to enable the article to be coupled to the electrical connector. For example, the electrical connector may include a member positioned opposite the electrical connector contacts and configured to grip the article between them. This member, or any other part of the electrical connector, may be configured not to apply substantially any force toward the flow path to the article.

[0269] Figure 31 shows an aerosol supply device 200 and article 300 according to a non-limiting embodiment of the present invention. The aerosol supply device 200 is substantially the same as that shown in Figure 1, and therefore only additional features are described below. The article 300 shown in Figure 31 is shown to be similar to the article 300 shown in Figure 29, except that the air inlet 316 is formed through the aerosol generator 304, as shown in Figure 31. In some embodiments, the aerosol supply device 200 can be configured to position and operate with any of the articles 300 described above.

[0270] The aerosol supply device includes a conduit 240 within a main body 202 through which air can flow. A first opening 242 of the conduit 240 is configured as an opening in the device housing 204 and defines a device air inlet 244 into which air can be drawn during use. In Figure 27, the device air inlet is shown on the outer surface of the device housing 204. The outer surface is understood to mean the surface that can be grasped by the user, rather than the inner surface defined by the receptacle 208. A second opening of the conduit 240 is configured as an air outlet 248 communicating with a chamber 206.

[0271] As shown in Figure 31, the device air inlet 244 and the device air outlet 248 are longitudinally offset from each other. In this embodiment, this is achieved by providing two longitudinally offset conduits that are in fluid communication with each other. The device air inlet 244 and the air outlet 246 can be directly in fluid communication by a single conduit. The conduit 240 may take any suitable path between the device air inlet 244 and the device air outlet 248. In some embodiments, the device air inlet 244 and the device air outlet 248 may be longitudinally aligned. In such cases, the conduit 240 may be a single conduit. In any of the above cases, the conduit 240 may be a separate component or may be formed integrally with the device body 202 and / or housing 204.

[0272] A sealing member 250 is provided within the receptacle 208. The sealing member 250 defines at least a portion of the conduit 240. The sealing member 250 is configured to engage sealably with the article 300 when the article 300 is at least partially received by the aerosol supply device 200. In particular, the sealing member 250 is configured to form a seal over the article air inlet 314. This may be achieved by the sealing member 250 being configured to align with the article air inlet 314 when in use. To engage sealably should be understood as, when in use, substantially only air drawn in through the device air inlet 244 is received by the aerosol product air inlet 314. That is, during operation, the sealing member can provide a seal around the article air inlet 314, thereby defining a substantially closed air path between the device air inlet 314 and the article air outlet 318. The sealing member 250 is shown as tubular and includes a wall 252 and a rim 254 for contacting and sealing with the article 300. The sealing member 250 may define the device air outlet 248.

[0273] As shown in Figure 31, the sealing member 250 protrudes from the receptacle 208. That is, the sealing member 250 rises from the inner surface of the receptacle 208 toward the longitudinal axis. In some embodiments, the sealing member 250 may be configured to be elastic so that the sealing member 250 or a portion thereof can deform during use. For example, the wall 252 and / or rim 254 may deform. The sealing member 250 may contain silicone to provide elasticity. In some embodiments, the sealing member 250 may be configured to necessarily deform during use. By allowing and / or requiring deformation of the sealing member 250 during use, a better seal than that of a rigid sealing member may be achieved. The seal between the sealing member 250 and the article 300 may be further improved by tapering a portion of the sealing member 250, for example, the rim 254. This provides further flexibility of the sealing member.

[0274] Without such a sealing arrangement as shown in Figure 31, it can be envisaged that a user's inhalation and / or exhalation may cause condensation to form within the device 200 either inside or outside the flow path. In particular, one problematic location where condensation may form is on the device electrical connector contacts 232. Condensation on the device electrical connector contacts 232 may cause a change in the resistance of the electrical connector itself and / or affect the physical connection between the device electrical connector contacts 232 and the article contact area. Consequently, the power provided to the article 300, and in particular to the aerosol generator 304, may be different from that intended, thus affecting the effectiveness of the article 300. Therefore, problems relating to condensation in the device 200, in particular on the device electrical connector contacts 232, may be avoided by isolating the flow path from the device electrical connector contacts 232. As mentioned above, this may be achieved by providing a device sealing member 250 that sealingly engages with the article 300.

[0275] As mentioned above, the aerosol supply device 200 can be configured to position any of the above-described embodiments of the article 300.

[0276] The device 300 may also include a second conduit 260 identical to the first conduit 250 described above, as shown, for example, in Figure 32. As shown in Figure 32, this allows for use with an article 300 having two air inlets. Figure 32 shows that the conduit 260 includes a second device air inlet 264 defined by a second opening in the housing 204 and a second device air outlet 268 communicating with the chamber 206. Furthermore, a second sealing member 270 identical to the first sealing member 250 is shown. In this regard, the configuration of the first sealing member 250 described above and the advantages arising therefrom are equally applicable to the second sealing member 270. Furthermore, the use of opposing sealing members can help position the article within the receptacle. The first and second sealing members 250, 270 may be different. For example, the first and second sealing members 250, 270 may differ in cross-sectional size and / or shape. The first and second sealing members 250, 270 may contain different materials. As shown in Figure 32, the second conduit 270 is diametrically opposite to the first conduit 240. In particular, the first and second sealing members 250, 270 face each other. In some embodiments, the first and second conduits 240, 260 may be different. For example, the first device air inlet 244 and air outlet 348 may be longitudinally offset, while the second device air inlet 264 and air outlet 268 are aligned. The first and second conduits 240, 260 may or may not be diametrically opposite.

[0277] In FIG. 32, the second sealing member 270 protrudes from the receptacle 208 and is shown so as to face the first sealing member 260. As mentioned above, the first and second sealing members may or may not be diametrically opposite to each other. Positioning the first and second sealing members 250, 270 opposite each other provides means for arranging and / or gripping the article 300 therebetween. As shown in FIG. 32, the electrical connector 230 may grip the article 300 by the device electrical connector contacts 232 exerting a force on the article electrical contacts. However, the gripping provided by the device electrical connector contacts 232 and the article contacts may or may not be sufficient to hold the article 300 within the receptacle 208. Accordingly, the opposing first and second sealing members 250, 270 may provide additional holding means. The first and second sealing members 250, 270 may have additional advantages other than gripping and / or positioning the article 300 within the receptacle 208. For example, the first and second sealing members 250, 270 may provide support for the article. That is, the first and second sealing members 250, 270 may limit and / or prevent unintended twisting or general movement of the article within the receptacle 208. Such movement may cause bending and / or weakening of the article during engagement with the device electrical connector 230. Furthermore, movement may reduce the reliability of the electrical connection between the article 300 and the device 200.

[0278] It may be desirable to detect the use of the aerosol supply system. For example, the aerosol product 300 may be consumed after a certain number of typical inhalations and / or duration, and it is desirable to communicate this to the user. By detecting and storing usage data, the device may be configured to provide feedback to the user. This may be achieved, for example, by providing a sensor configured to detect changes in airflow in the first conduit 240 and / or the second conduit 260. Detection of changes in airflow may indicate use. The sensor may be an acoustic sensor, such as a microphone. The sensor may be a puff detector. The sensor may be located adjacent to or inside the conduit. Additionally or alternatively, the sensor may be a pneumatic sensor located inside the conduit to detect changes in flow. By providing the sensor inside the conduit, more reliable detection of attributes may be achieved.

[0279] As described above, the aerosol supply device 200 can be configured to position and operate with any of the above embodiments of article 300.

[0280] An exemplary device electrical connector 230, used in the aerosol supply device of Figures 31 and 32 and potentially used with any of the articles 300 described above, is described here in detail with reference to Figure 20. As briefly described above, the device electrical connector 230 includes a series of device electrical connector contacts 232 for supplying power to the article electrical contacts. Each of the device electrical connector contacts 232 is configured to be elastically flexible upon engagement with the article 300. In Figures 31 and 32, the device electrical connector contact 232 bends upon engagement with the protruding panel 390 on which the article electrical contacts are located (320). The device electrical connector contact 232 may be configured to engage with any of the articles 300 described above. In some embodiments, the device electrical connector contact 232 may first engage with another part of the article 300. For example, the device electrical connector contact may bend upon engagement with the body 324. In Figures 20, 31, and 32, the electrical connector contact is a spring lever connector.

[0281] Each device electrical connector contact 232 is molded to have a leading portion for initial engagement with the protruding panel and a curved portion for contact with the article electrical contacts when in use. As shown in Figures 20, 31, and 32, the leading portion is primarily curved and inclined with respect to the longitudinal-transverse plane. In some embodiments, the leading portion may be straight. By inclining the leading portion 238 as shown, resistance to coupling may be reduced, and therefore the force required to couple the device and the article may be reduced. Furthermore, by reducing the force required by the user to couple the device 200 and the article 300, less force acts on the components of the device and / or article, thus also reducing the risk of damaging the device and / or article during insertion. The aerosol supply device 200, in particular the device electrical connector contacts, may be configured to supply power to any of the articles 300 described above. For example, an article 300 in which the exposed electrical contact area 320 is not on the protruding panel.

[0282] In some embodiments of the aerosol generators and different arrangements of articles described above, the aerosol-generating material is formed in a configuration other than as an aerosol-generating layer. In embodiments, the aerosol-generating material is in the form of an aerosol-generating segment. An aerosol-generating segment generally comprises a solid material. Such a solid material may be shredded tobacco. For example, an aerosol-generating material arranged as an aerosol-generating segment may comprise a plurality of individual aerosol-generating material pieces. The aerosol-generating material may also comprise individual tobacco material pieces. In embodiments, the aerosol-generating material comprises a plurality of strips, beads, or pellets. In embodiments, the aerosol-generating segment is a mass of material.

[0283] In the embodiments, the aerosol-generating segment includes a material body. The aerosol-generating material is non-liquid. In such embodiments, the material body includes a rod of the aerosol-generating material, for example, a tobacco rod. For example, the material body may include shredded tobacco material. The material body may be formed into a rod. In some embodiments, the material body includes cut rag tobacco formed into a rod. The aerosol-generating material may include tobacco material. The aerosol-generating material may include extruded tobacco. The aerosol-generating material may include reconstituted tobacco.

[0284] The aerosol-generating material, formed as a solid material, may contain nicotine. The aerosol-generating material may contain tobacco, be made from tobacco, or be essentially made from tobacco. In some embodiments, the aerosol-generating material does not contain tobacco.

[0285] In any of the embodiments described above, heating the article provides a relatively constant release of volatile compounds into an inhalable medium. In the embodiments described above, the aerosol-generating segment is a mass of material. The article may include a mouthpiece end section. A tubular element may be located between the aerosol-generating material and the mouthpiece end section. The article may include a ventilation area in the mouthpiece end section. The mouthpiece end section may define a mouthpiece configured to be positioned between the user's lips.

[0286] In any embodiment of the article described above, a resistance heating element or each resistance heating element is configured to heat substantially the entire aerosol-generating material. The aerosol-generating segment in the embodiment is at least substantially cylindrical. In the embodiment, the aerosol-generating segment is at least partially enclosed by a resistance heating layer. In the embodiment, the resistance heating element extends within the aerosol-generating segment. The resistance heating element may extend around the aerosol-generating segment. In the embodiment, the resistance heating element surrounds the aerosol-generating segment. In some arrangements, at least a portion of the flow path through the article passes through the aerosol-generating segment. The aerosol-generating segment may define a portion of the air path. In the embodiment, a first type of electrical contact and a second type of electrical contact are exposed from the aerosol-generating segment.

[0287] 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. Filler components may be present in amounts of 0 to 20 wt% of the tobacco material, or in amounts of 1 to 10 wt% of the composition. In some embodiments, filler components are absent. In the tobacco materials described herein, the tobacco material contains an aerosol-forming agent material. In this context, “aerosol-forming agent material” is an agent that promotes aerosol formation. Aerosol-forming agent materials may promote aerosol formation by promoting the initial vaporization and / or condensation of gas into inhalable solid and / or liquid aerosols. In some embodiments, aerosol-forming agent materials may improve the delivery of flavor from the aerosol-forming material. Generally, the aerosol-forming material of the present invention may include any suitable aerosol-forming agent material or agent, including those described herein.

[0288] Paper-reconstructed tobacco refers to tobacco material formed by a process in which tobacco raw materials are extracted with a solvent to obtain an extract of soluble substances and a residue containing fibrous material, and then the extract (usually after concentration and optionally after further processing) is recombined with fibrous material from the residue (usually after purification of the fibrous material and optionally with the addition of 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.

[0289] 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 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. Articles for aerosol supply devices, Aerosol generating materials and A resistance heating layer comprising a resistance heating element configured to heat at least a portion of the aerosol generating material in order to generate an aerosol, wherein the aerosol generating material is located on the resistance heating layer, An exposed electrical contact area of ​​a first type of electrical contact configured to be electrically connected to the electrical connector of the aerosol supply device, An exposed electrical contact region of a second type of electrical contact configured to be electrically connected to the electrical connector of the aerosol supply device, wherein the resistive heating element is at least a portion of the conductive path between the first type of electrical contact and the second type of electrical contact, An opening in the article that defines an air inlet for a flow path through which an aerosol can flow, and Includes, The exposed electrical contact area does not substantially overlap with the air path through the article. Goods.

2. The article according to claim 1, comprising a support, wherein the resistance heating layer is located on the support.

3. The article according to claim 1 or 2, comprising a body defining at least a portion of the flow path, wherein the resistance heating layer is located on the body.

4. The article according to claim 3, wherein the air inlet is defined by the main body.

5. The article according to claim 4, wherein the main body defines the main body wall, and the air inlet is defined by the main body wall.

6. The article according to any one of claims 3 to 5, wherein at least one of the exposed electrical contact areas of the first type and the second type of electrical contact is supported by the body.

7. The article according to claim 6, wherein each of the exposed electrical contact areas of the first type and the second type of electrical contacts is supported by the body.

8. The article according to any one of claims 2 to 6, wherein the majority of the exposed electrical contact areas of the first type and the second type of electrical contacts overlap with the support.

9. The article according to claim 1 or 2, wherein the air inlet is formed by penetrating the resistance heating layer.

10. The article according to claim 9, as dependent on claim 2, wherein the air inlet is defined in the support.

11. The article according to any one of claims 1 to 10, comprising an aerosol generating layer containing an aerosol generating material, wherein the aerosol generating layer is located on the resistance heating layer.

12. The article according to any one of claims 1 to 11, comprising a wrap configured to enclose at least a portion of the article, wherein the air inlet is formed in the wrap, and at least one of the exposed electrical contact areas of the first type and the second type of electrical contacts does not overlap with the wrap.

13. Articles for aerosol supply devices, Aerosol generating materials and A resistance heating layer, wherein the aerosol generating material is located on the resistance heating layer, and at least a portion of the resistance heating layer forms a resistance heating element configured to heat at least a portion of the aerosol generating material in order to generate an aerosol. The first type of electrical contact, A second type of electrical contact, wherein the resistive heating element is at least a portion of the conductive path between the first type of electrical contact and the second type of electrical contact, A body that at least partially defines a channel through which an aerosol can flow within the article, Includes, At least one of the first type of electrical contact and the second type of electrical contact is offset from the body. Goods.

14. The article according to claim 13, wherein the resistance heating layer forms the first type of electrical contact and the second type of electrical contact.

15. The article according to claim 14, comprising a protruding panel that protrudes from the main body, wherein at least one of the first type of electrical contact and the second type of electrical contact is located on the protruding panel.

16. The article according to claim 15, wherein the protruding panel protrudes from the longitudinal end of the main body.

17. The article according to claim 16, wherein the protruding panel protrudes from the longitudinal side surface of the main body.

18. The article according to any one of claims 1 to 17, an aerosol supply device configured to receive at least a portion of the aforementioned article and An aerosol supply system equipped with the following features.

19. The main unit and A receptacle within the body defining a chamber configured to receive at least a portion of an aerosol product, and a conduit within the body through which air can flow, including an air outlet communicating with the chamber, A sealing member within the receptacle is configured to define at least a portion of the conduit and to engage in a sealable manner with the aerosol product in the chamber. An aerosol supply device equipped with the following features.

20. Articles containing aerosol-generating materials, The aerosol supply device according to claim 19 and An aerosol supply system equipped with the following features.

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