Aerosol supply device

Abstract

The aerosol-forming article (110) comprises a first surface containing an aerosol-generating material (306), a second surface opposite the first surface such that an airflow path is defined between the first surface and the second surface, and an inlet (508) that allows air to flow into the aerosol-forming article between the first surface and the second surface, the inlet (508) being at least 0.15 mm 2 It has an area of ​​.

Description

Technical Field

[0001] The present invention relates to an article for generating aerosols. Background Art

[0002] Smoking articles such as cigarettes and cigars burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles that burn tobacco by creating products that release compounds without burning. An example of such a product is a heating device that releases compounds by heating rather than burning a material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] In one aspect, there is provided an aerosol-forming article. The aerosol-forming article comprises a first surface containing an aerosol-generating material, a second surface facing the first surface such that an airflow path is defined between the first surface and the second surface, and an inlet that allows air to flow into the aerosol-forming article between the first surface and the second surface. The inlet has at least 0.15 mm 2 area.

[0004] The inlet has at least 0.20 mm 2 area. The inlet has at least 0.25 mm 2 area. The inlet has at least 0.30 mm 2 area. The inlet has at least 0.35 mm 2 area. The inlet has at least 0.37 mm 2 area. The inlet has at least 0.40 mm 2 area. The inlet has at least 0.45 mm 2 area. The inlet has at least 0.50 mm 2 area. The inlet has at least 0.51 mm 2may have an area of

[0005] The inlet may be 5 mm 2 or less in area. The inlet may be 4 mm 2 or less in area. The inlet may be 3 mm 2 or less in area. The inlet may be 2.61 mm 2 or less in area. The inlet may be 1.91 mm 2 or less in area. The inlet may be 1.21 mm 2 or less in area. The inlet may be 0.86 mm 2 or less in area. The inlet may be 0.51 mm 2 or less in area. The inlet may be substantially 0.51 mm 2 in area. The inlet may be substantially 0.37 mm 2 in area.

[0006] The aerosol-forming article may be formed from a layered structure. The layered structure may comprise a first layer defining a first surface and a second layer defining a second surface. The layered structure may be a folded layered structure. The layered structure may comprise an intermediate layer. The inlet may be formed in the intermediate layer. The aerosol-forming article may further comprise a flow control feature arranged such that air from the inlet impinges on the flow control feature, and the flow control feature is configured to reduce the velocity of the air. The flow control feature may be formed by a cross member. The flow control feature may be formed in the intermediate layer. The flow control feature may be upstream of the aerosol-generating material. The inlet may be formed by removing a portion of the intermediate layer. The layered structure may further comprise an additional intermediate layer between the intermediate layer and the first layer. The layered structure may further comprise an additional further intermediate layer between the intermediate layer and the second layer. The air flow path may not include an obstruction between the first surface and the second surface in the aerosol-generating material. The second surface may comprise the aerosol-generating material. The first surface may be substantially flat. The second surface may be substantially flat.

[0007] In yet another embodiment, an aerosol supply system is provided. The aerosol supply system comprises one of the aerosol-forming articles described above and an aerosol supply device configured to heat the aerosol-generating material to generate an aerosol.

[0008] Here, an embodiment will be described as merely an example, with reference to the attached drawings. [Brief explanation of the drawing]

[0009] [Figure 1] This is a side view showing an aerosol supply system. [Figure 2] This is a schematic cross-sectional view of an article in a plane parallel to the longitudinal axis of the article. [Figure 3] This is an exploded view showing the substrate and aerosol-generating material. [Figure 4A] This is an exploded view showing the middle layer of an item. [Figure 4B] This is a cross-sectional view showing the third intermediate layer of the article. [Figure 4C] This is a cross-sectional view of the third intermediate layer showing the flow control feature section. [Figure 5] This graph shows the amount of aerosol being transported, plotted against the gap size. [Figure 6A] This graph shows the pressure drop for various inlet areas. [Figure 6B] This graph shows the amount of aerosol delivered for various inlet sizes. [Figure 7A] This graph shows the amount of aerosol delivered to articles with different characteristics, including different outlet areas. [Figure 7B] This graph shows the amount of aerosol delivered relative to the outlet area. [Figure 8] Figure 7A is an exploded view showing the structural components of various articles that were tested to generate the data shown. [Figure 9] This graph shows the aerosols delivered for articles with different properties. [Figure 10] Figure 9 is an exploded view showing the structural components of various articles that were tested to generate the data shown. [Figure 11] This shows a schematic cross-sectional view of an article in a plane perpendicular to its longitudinal axis. [Modes for carrying out the invention]

[0010] As used herein, the term “aerosol-generating material” refers to a material that can generate an aerosol when, for example, it is heated, irradiated, or to which energy is applied in any other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain active substances and / or flavorings. The aerosol-generating material may also contain any plant-based material, such as tobacco-containing material, and may include, for example, one or more tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The aerosol-generating material may also contain other non-tobacco products, which may or may not contain nicotine, depending on the product. The aerosol-generating material may be in the form of, for example, a solid, liquid, gel, or wax. The aerosol-generating material may also be, for example, a combination or blend of materials. The aerosol-generating material may also be known as “smoked material.”

[0011] The aerosol-generating material may include a binder and an aerosol-forming agent. Optionally, an active substance and / or filler may also be present. Optionally, a solvent such as water may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant materials. In some embodiments, the aerosol-generating material is substantially free of tobacco.

[0012] The aerosol-generating material may include or may be an amorphous solid. The amorphous solid may be a monolithic solid. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material capable of holding some fluid, such as a liquid, within the amorphous solid. In some embodiments, the aerosol-generating material may include, for example, about 50% by weight, 60% by weight, or 70% by weight of amorphous solid, or about 90% by weight, 95% by weight, or 100% by weight of amorphous solid.

[0013] The aerosol-generating material may include an aerosol-generating film. The aerosol-generating film may optionally include, or be, sheets that can be shredded to form shredded sheets. The aerosol-generating sheets or shredded sheets may not substantially contain tobacco.

[0014] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or their components) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0015] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0016] 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.

[0017] 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.

[0018] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of one or more aerosol-generating materials that can be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0019] 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.

[0020] 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.

[0021] In some embodiments, a non-combustible aerosol supply system, for example, the non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate to which energy can be supplied to distribute power in the form of heat to an aerosol-generating material or heat-transferring material located near the heat-generating power source.

[0022] 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.

[0023] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a suction nozzle and / or an aerosol modifier.

[0024] An aerosol generating device can receive an article containing an aerosol generating material for heating. In this context, “article” is a component that contains or includes an aerosol generating material which is heated during use to volatilize the aerosol generating material, and optionally contains or includes other components during use. The user may insert the article into the aerosol generating device before the article is heated to generate an aerosol, after which the user inhales the aerosol. The article may be of a predetermined or specific size, for example, configured to be placed in a heating chamber of a device sized to receive the article.

[0025] Referring to Figure 1, the aerosol supply system 10 comprises an aerosol supply device 100 for generating an aerosol from an aerosol-generating material. The aerosol supply system 10 further comprises a replaceable article 110 containing the aerosol-generating material. Schematically, the aerosol-forming device 100 may be used to heat the article 110 to generate an aerosol or other inhalable medium to be inhaled by a user of the device 100. In this example, the aerosol-forming article 110 is intended for use with the aerosol supply device 100. However, in other examples, the aerosol-forming article 110 may be used as an aerosol supply device (for example, an integrated aerosol supply system that may be single-use).

[0026] The aerosol forming device 100 comprises a main body 102. The housing structure surrounds and accommodates various components of the main body 102. An article opening 104 is formed at one end of the main body 102 through which an article 110 can be inserted for heating by the aerosol generator 200.

[0027] Device 100 may also include a user-operable control element 150, such as a button or switch, which activates Device 100 when pressed. For example, a user may turn on Device 100 by operating the switch 150.

[0028] The aerosol generator 200 defines a longitudinal axis that aligns with the axis of the article 110.

[0029] During use, article 110 may be fully or partially inserted into the aerosol generator 200 and may be heated by one or more components of the aerosol generator 200.

[0030] Device 100 includes an apparatus for heating an aerosol-generating material. The apparatus includes an aerosol-generating assembly, a controller (control circuit), and a power source. The apparatus forms part of the main body 102. The aerosol-generating assembly is configured to heat the aerosol-generating material of an article 110 inserted through an article opening 104 so that an aerosol is generated from the aerosol-generating material. The power source supplies power to the aerosol-generating assembly, which converts the supplied electrical energy into thermal energy for heating the aerosol-generating material. The power source may be a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries.

[0031] A power source may be electrically connected to the aerosol generation assembly to heat the aerosol generation material by supplying power under the control of a controller when needed. The control circuit may be configured to start and stop the aerosol generation assembly based on user input. User input may be a button press or the opening of a device door (e.g., a door covering a consumable receiving receptacle). The control circuit may be configured to start and stop automatically, for example, when an article is inserted.

[0032] An aerosol generation assembly may comprise various components for heating an aerosol-generating material via an induction heating process. Induction heating is a process of heating a conductive heating element (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an induction element, for example, one or more inductor coils, and a device for passing a fluctuating current, such as an alternating current, through the induction element. The fluctuating current in the induction element generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor (heating element) appropriately positioned relative to the induction element, generating eddy currents inside the susceptor. The susceptor has electrical resistance to eddy currents, and therefore, the flow of eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor contains a ferromagnetic material such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses within the susceptor, i.e., by a change in the orientation of magnetic dipoles in the magnetic material as a result of alignment with the fluctuating magnetic field. In induction heating, compared to heating by conduction, for example, heat is generated inside the susceptor, allowing for rapid heating. Furthermore, since no physical contact is required between the inductive element and the susceptor, it becomes possible to increase the degree of freedom in construction and application.

[0033] Referring to Figure 2, article 110 further comprises a first substrate 302 and a second substrate 304. Each of the first and second substrates 302, 304 is made from high-grams-per-square-meter paper (high-GSM paper) backed with aluminum foil, e.g., 70 gsm to 400 gsm or 100 gsm to 400 gsm, e.g., 240 gsm paper or any paper having more than 400 gsm. In some embodiments, high-GSM paper backed with aluminum foil may be considered as higher-GSM paper backed with aluminum foil. In some embodiments, the high-GSM paper may have a thickness of 0.125 mm or 0.35 mm. In other embodiments, the high-GSM paper may have a greater or lesser thickness. In some embodiments, the first and second substrates 302, 304 may be considered as a two-layer material, such as a card or paper backing with a metal surface. In other words, each of the first and / or second substrates 302, 304 comprises a layer of aluminum (i.e., a heating layer) and a layer of paper or board material (i.e., a structural layer). In other examples, instead of the aluminum layer, a layer of another metal or metal alloy may be used to provide the heating layer of the first and / or second substrates 302, 304.

[0034] Article 110 further comprises a first aerosol-generating material 306 attached to a first substrate 302. Article 110 further comprises a second aerosol-generating material 308 attached to a second substrate 304. The first and second aerosol-generating materials 306 and 308 are aerosol gels. The aerosol-generating materials 306 and 308 are attached directly to the heating layers of the first and second substrates 302 and 304. This means that the first and second substrates 302 and 304 are positioned such that the heating layer is on the inside of article 110 and the structural layer is on the outside of the heating layer outside of article 110.

[0035] Article 110 is configured such that first and second aerosol-generating materials 306, 308 face each other. Article 110 further comprises at least one intermediate layer (not shown in Figure 2) separating the first and second aerosol-generating materials 306, 308. The at least one intermediate layer will be described in more detail below in relation to Figures 4A to 4C. During use, the heating layer, more specifically the aluminum foil, can be induced by, for example, induction technology to generate heat, thereby heating the aerosol gel. Heating the aerosol gel generates an aerosol that can be used by the user, for example, by inhalation. The first and second aerosol-generating materials 306, 308 at least partially define an airflow path between them. The aerosol generated by the first and second aerosol-generating materials 306, 308 can travel along the airflow path to the user. Article 110 comprises an oral end and a distal end opposite the oral end. The oral end is the end from which the user can use / inhale the aerosol. In some embodiments, the article may have a mouthpiece located at the mouth end. The mouthpiece may be made of a different material from the rest of the article. The mouthpiece may have a different structure from the rest of the article.

[0036] Article 110 is configured such that a first aerosol-generating material 306 and a second aerosol-generating material 308 are separated by a gap d. The size of the gap d may affect the air velocity and / or pressure in the airflow path during use, for example, when inhaled by a user. Surprisingly, the inventors have found that certain values ​​of the gap d result in more aerosol being generated and / or delivered to the user. This may be due to the air velocity and / or pressure in the airflow path, which affect the degree to which the aerosol-generating material is heated (e.g., due to the cooling effect of the air), and / or the amount of aerosol delivered to the mouth end and / or the user by the airflow.

[0037] Therefore, if the airflow velocity is not sufficiently high, the amount of aerosol carried by the airflow will be insufficient, and for example, aerosol droplets may be deposited before reaching the mouth end. If the gap d is too small, the flow velocity will be too high, and the temperature at which the aerosol-generating material is heated will likely be lower, which may result in less aerosol generation.

[0038] In this embodiment, the gap d is 0.9 mm or greater. Advantageously, the inventors have found that a d of 0.9 mm or greater can mean a remarkable increase in the mass of aerosol delivered to the user compared to, for example, a system where d is less than 0.9 mm. Even more surprisingly, this effect is found to be even greater when d is 1.34 mm or greater. Even more surprisingly, when d exceeds 1.8 mm, such as substantially equal to 1.84 mm, the mass of aerosol generated and / or delivered can be even greater. When d increases beyond 1.84 mm, the mass of delivered aerosol may plateau or decrease. In some embodiments, d may be 4 mm or less, e.g., 2.5 mm or less, 2.34 mm or less, 2.2 mm or less, 2.1 mm or less, 2.0 mm or less, or 1.9 mm or less. When d is reduced from 4 mm to 1.84 mm, more aerosol can be delivered to the user.

[0039] In this embodiment, the article has an elongated shape. In other embodiments, the article may not have an elongated shape, for example, the article may have a circular or square shape. In this embodiment, the article is substantially flat. In other embodiments, the article is not flat. In this embodiment, the first and / or second aerosol-generating material is an aerosol gel. In other embodiments, the first and / or second aerosol-generating material is not an aerosol gel, but for example, an aerosol solid or aerosol liquid. In this embodiment, the aerosol is generated by induction heating. In other embodiments, the aerosol is not generated by induction heating, and heating is performed by another method, for example, by convection or conduction. In this embodiment, the substrate contains a component that can be induced by induction techniques to generate heat. In other embodiments, the substrate does not contain a component that can be induced by induction techniques to generate heat, for example, the substrate may contain only wood or paper. In this embodiment, the first substrate is the same as the second substrate. In other embodiments, the first substrate is different from the second substrate. In this embodiment, the aluminum foil is placed in contact with the aerosol-generating material. In other embodiments, the aluminum foil is not positioned in contact with the aerosol-generating material; for example, high-GSM paper is positioned between the aluminum foil and the aerosol-generating material. In this embodiment, the first and / or second substrates are made from high-GSM paper backed with aluminum foil. However, in other embodiments, the first and / or second substrates are not made from high-GSM paper backed with aluminum foil; for example, the first and / or second substrates may be made from copper foil or another material capable of generating heat by induction. In this embodiment, the first substrate and the first aerosol-generating material are positioned in the same way as the second substrate and the second aerosol-generating material. However, in other embodiments, the first substrate and the first aerosol-generating material are positioned in a different manner than the second substrate and the second aerosol-generating material are positioned.

[0040] Referring to Figure 3, the first substrate 302 has an elongated shape that extends longitudinally. The longitudinal direction extends from the mouth end to the distal end. The first aerosol-generating material 306 is arranged in a series of first individual parts 402-410 that are sequentially arranged along the longitudinal direction. The series of first individual parts 402-410 are separated and / or spaced apart from each other. Similarly, the second substrate 304 has an elongated shape that is elongated along the longitudinal direction. The second aerosol-generating material 308 is arranged in a series of second individual parts 412-420 that are sequentially arranged along the longitudinal direction. During use, the individual parts of the aerosol-generating material are heated sequentially. For example, for each inhalation by the user, only one of the individual parts is heated to generate an aerosol. However, in other embodiments, multiple individual parts may be heated to generate an aerosol for each inhalation by the user.

[0041] In this embodiment, each individual part is shaped like a square. In other embodiments, each individual part is not shaped like a square; for example, each individual part is shaped like a circle or a rhombus. In this embodiment, the individual parts are identical to each other. In other embodiments, the individual parts are not identical to each other. In this embodiment, the first individual part is identical to the second individual part. In other embodiments, the first individual part is not identical to the second individual part; for example, the second individual part may have a different shape from the first individual part. In this embodiment, the first and / or second aerosol-generating material is arranged in a series of individual parts. In other embodiments, the first and / or second aerosol-generating material is not arranged in a series of individual parts; for example, the first and / or second continuous aerosol-generating material may be arranged in strips, or in a continuous regular or continuous irregular shape.

[0042] Referring to Figure 4A, article 110 comprises a first intermediate layer 502. The first intermediate layer 502 has an elongated, substantially flat shape extending along its longitudinal direction. The first intermediate layer 502 is configured to bond to the first aerosol-generating material 306. The first intermediate layer 502 has a series of first holes. Each of the first holes has a shape complementary to the corresponding first individual portions 402-410. The first intermediate layer 502 is configured to abut the first aerosol-generating material 306 and the first substrate 302 such that each of the first individual portions 402-410 fits inside the corresponding hole of the first intermediate layer 502.

[0043] In this embodiment, a substantially flat surface can be formed by the first intermediate layer and the first aerosol-generating material extending through it. In this embodiment, the thickness of the first intermediate layer is substantially the same as the thickness of the first aerosol-generating material. In other embodiments, the first intermediate layer and the first aerosol-generating material do not form a substantially flat surface; for example, the first aerosol-generating material extends beyond the first intermediate layer. In this embodiment, the first intermediate layer comprises a series of first holes. In other embodiments, the first intermediate layer does not comprise a series of first holes; for example, the first intermediate layer may comprise a single hole having a shape complementary to the shape of the first aerosol-generating material.

[0044] Referring to Figure 4A, article 110 further comprises a second intermediate layer 504. The second intermediate layer 504 has a substantially flat shape that is elongated along its longitudinal direction. The second intermediate layer 504 is configured to bond to the second aerosol-generating material 308. The second intermediate layer 504 comprises a series of second holes. Each of the series of second holes has a shape complementary to the corresponding second individual portions 412-420. The second intermediate layer 504 is configured to abut the second aerosol-generating material 308 such that each of the second individual portions 412-420 fits inside its corresponding second hole. In this way, a substantially flat surface can be formed by the second intermediate layer 504 and the second aerosol-generating material 308 extending through it. The thickness of the second intermediate layer 504 is substantially the same as the thickness of the second aerosol-generating material 308.

[0045] In this embodiment, a substantially flat surface can be formed by the second intermediate layer and the second aerosol-generating material. In this embodiment, the thickness of the second intermediate layer is substantially the same as the thickness of the second aerosol-generating material. In other embodiments, the second intermediate layer and the second aerosol-generating material do not form a flat surface, for example, the second aerosol-generating material extends beyond the second intermediate layer. In this embodiment, the second intermediate layer comprises a series of second holes. In other embodiments, the second intermediate layer does not comprise a series of second holes, for example, the second intermediate layer may comprise a single hole having a shape complementary to the shape of the second aerosol-generating material.

[0046] Referring to Figure 4A, article 110 further comprises a third intermediate layer 506. The third intermediate layer 506 has a substantially flat shape that is elongated along its longitudinal direction. The third intermediate layer 506 is provided with an inlet opening 508 at a first end along its longitudinal direction. The pressure drop through article 110 may be important for the user experience. It has been found that to increase the mass of aerosol delivered to the user (which may also be important for the user experience), it may be beneficial to eliminate obstacles in the airflow path close to the aerosol-generating material and increase the outlet area. However, when these features are implemented, the pressure drop may be too small. Therefore, it may be beneficial to vary the inlet area to control the pressure drop through article 110.

[0047] The third intermediate layer 506 further comprises an outlet opening 510 at a second end along the longitudinal direction of the third intermediate layer 506. The first end is on the opposite side of the second end along the longitudinal direction. The outlet opening 510 corresponds to the mouth end of the article 110. The user can inhale an aerosol through the outlet opening 510. The applicant has also found, surprisingly, that the area of ​​the outlet opening 510 directly affects the mass of aerosol that can be generated and / or delivered to the user. Smaller outlet openings tend to result in less aerosol generation. Conversely, larger outlet openings tend to result in more aerosol generation. Furthermore, increasing the width of the outlet opening rather than its thickness tends to increase the area, which in turn tends to increase aerosol generation more significantly.

[0048] The third intermediate layer 506 further comprises a conduit that fluidly connects an inlet opening 508 to an outlet opening 510. The inlet opening 508 allows air to enter the conduit. The third intermediate layer 506 is configured to create separation and / or a gap d between the first and second aerosol-generating materials 306, 308. Thus, the separation by the third intermediate layer 506 creates an airflow path between the first and second aerosol-generating materials 306, 308. The conduit is positioned to at least partially overlap the first and second aerosol-generating materials 306, 308. The third intermediate layer 506 further comprises an upper surface configured to bond to and / or abut against the first intermediate layer 502. The third intermediate layer 506 further comprises a lower surface opposite to the upper surface. The lower surface is configured to bond to and / or abut against the second intermediate layer 504. The direction extending from the upper surface to the lower surface is perpendicular to the longitudinal direction. The direction extending from the top surface to the bottom surface is the dimension in which the thickness is determined. The thickness of the third intermediate layer 506 defines the size of the gap d. In other words, the thickness of the third intermediate layer 506 is the same as the distance d of the gap. In some embodiments, the size d of the gap is determined by the thickness of the third intermediate layer 506 in addition to the thickness of the adhesive layer used to bond the third intermediate layer 506 to the first and second intermediate layers 502, 504. The third intermediate layer 506 includes a bridge section 512 that extends across the width of the third intermediate layer 506. The width is determined in directions perpendicular to both the longitudinal and thickness directions. Referring to Figure 4B, the bridge section 512 has a thickness less than the thickness of the third intermediate layer 506. Advantageously, this means that the bridge section tends not to obstruct airflow paths and / or conduits. In this embodiment, the bridge section is positioned close to the bottom surface of the third intermediate layer. In other embodiments, the bridge section may not be positioned close to the bottom surface, for example, it may be positioned close to the top surface of the third intermediate layer. In some embodiments, the bridge section may be positioned in the intermediate portion between the top and bottom surfaces of the third intermediate layer, i.e., the bridge section is positioned such that the distance between the bridge section and the top surface is the same as the distance between the bridge section and the bottom surface. In some embodiments, the bridge section may be offset from one or more transverse members on the first and / or second intermediate layer.One or more transverse members may be considered as first and / or second intermediate layer components separating individual parts of the aerosol-generating material. In some examples, the bridging sections may be omitted to provide airflow paths (e.g., when a third intermediate layer is present in two individual parts).

[0049] Referring to Figure 4C, article 110 further comprises a flow control feature 514 positioned in the inlet opening 508. In this embodiment, the flow control feature 514 is a rib extending across the width of the inlet opening 508. The rib is T-shaped. The bottom of the T-shape is in contact with the second intermediate layer 504. The crossbar portion of the T-shape extends across the entire width of the inlet opening 508. The flow control feature 514 can guide air to a preferred region of the airflow path, thereby helping to increase the mass of aerosols carried by the airflow. Specifically, air entering the airflow path is forced to flow around the flow control feature 514, thereby allowing it to flow near the first and / or second aerosol-generating materials 306, 308. In this embodiment, the T-shape of the flow control feature 514 also forces incoming air into the corner region of the airflow path, improving mixing.

[0050] The flow control feature 514 can also influence the velocity and / or pressure drop of air in the airflow path during user inhalation. Without such a flow control feature, when a user inhales, the velocity of the air flowing into the inlet can be much greater than that of the stationary air in the airflow path. This can also reduce the mixing between the air flowing in through the inlet and the stationary air in the airflow path. This means that such an article tends to form a central jet of air, which adversely affects the performance of the article. Advantageously, the flow control feature tends to reduce and / or mitigate the central jet of air formed when a user inhales. Furthermore, the flow control feature tends to improve the mixing between the air flowing in through the inlet and the stationary air in the airflow path.

[0051] Furthermore, flow control features can increase the pressure drop within the airflow path. Specifically, flow control features tend to reduce the area of ​​the inlet opening when they are positioned within the inlet opening. As mentioned above, the smaller the inlet opening, the greater the pressure drop within the airflow path tends to be. In other words, flow control features can be considered to reduce the area of ​​the inlet opening when they are positioned within the inlet opening.

[0052] In this embodiment, the flow control feature is located at the inlet opening. In this embodiment, the flow control feature has a T-shape. In other embodiments, the flow control feature does not have a T-shape, and for example, the flow control feature has a cross shape, a rod shape, or a rectangular parallelepiped shape. In this embodiment, the flow control feature extends across the entire width of the inlet opening. In other embodiments, the flow control feature does not extend across the entire width of the inlet opening, and for example, the flow control feature extends across a limited portion of the inlet opening.

[0053] In the embodiments described above, the thickness of the third intermediate layer defines the size of the gap d. However, in other embodiments, one or more of the thicknesses of the first, second, and third intermediate layers define the size of the gap d. In some embodiments, the gap is defined by the space between the first and second aerosol-generating materials. In some embodiments, the gap is defined by the space between the first and second substrates. In some embodiments, the gap is defined by one or more of the thicknesses of the first intermediate layer, the second intermediate layer, the third intermediate layer, the first aerosol-generating material, the second aerosol-generating material, the first substrate, and the second substrate. In the embodiments described above, the article comprises first, second, and third intermediate layers. However, in other embodiments, the article does not comprise first, second, and third intermediate layers. In some embodiments, the article comprises one or more of the first, second, and third intermediate layers. In some embodiments, the inlet and / or outlet may be formed by bending or laser cutting through one or more of the intermediate layers.

[0054] Experiments were conducted on articles of various structures that support the remarkable advantages described herein. The results of the experiments on the articles are shown in the graphs in Figures 5, 6A, 6B, 7A, 7B, and 9. The articles used in the experiments were made from individual layers. The individual layers can be cut using a silhouette, CNC, or laser cutter. The cut profiles can then be arranged and bonded together. The fabricated articles can be tested in a laboratory equipped with a Borgwald facility for five or more repetitions, e.g., 10 repetitions. Silhouette cutting tends to be more reliable and less variable than, for example, CNC cutting.

[0055] Figure 5 shows a graph plotting the amount (mass) of aerosol delivered by airflow to the mouth end where the user can inhale the aerosol, for various experimental articles with different gap sizes d (where d is the separation distance between the first aerosol-generating material 306 and the second aerosol-generating material 308, as described above with reference to article 110 shown in Figure 2). Referring to Figure 5, it is surprising to see that when d = 1.34 mm, the amount of aerosol delivered by airflow increases. Furthermore, it can be seen that as the gap size d increases further, the mass of aerosol delivered increases even further. From Figure 5, it can be seen that when d = 1.84 mm, more aerosol is delivered, and the amount of aerosol generated levels off as d increases beyond 1.84 mm.

[0056] Referring to Figure 6A, graphs of pressure drop plotted for various inlet areas are shown. The articles tested to generate the data shown in Figures 6A and 6B have the same structure as structure A1 in Figure 8, as will be discussed later. From the graph in Figure 6A, it can be seen that the pressure drop increases as the inlet area decreases. 0.4 mm 2Articles with inlet openings of less than 0.15 mm in area have been found to experience relatively large pressure drops, which can negatively impact system performance and / or user experience. For example, this may prevent the user from inhaling and / or taking in sufficient aerosols from the article. In some embodiments, the inlet opening is 0.15 mm 2 Areas above, for example, 0.2 mm² 2 More than 0.21mm 2 The above is 0.37mm 2 More than 0.4mm 2 More than 0.4mm 2 Above, 0.5mm 2 Above, 0.6mm 2 Above, 0.7mm 2 Above, 0.8mm 2 or greater than 0.86 mm 2 The area may be greater than the above. In some embodiments, the entrance opening may have two holes.

[0057] Next, referring to Figure 6B, a graph is shown plotting the amount (mass) of aerosol delivered against various inlet areas for various articles with different inlet areas. Note that the articles tested for this graph are the same as those used in the graph in Figure 6A. From the graph in Figure 6B, 0.51 mm 2 It can be seen that the inlet area can result in the maximum amount of aerosol delivery. Furthermore, as can be seen from Figure 6B, the inlet area is 0.51 mm². 2 From 0.37mm 2 As it decreases, the amount of aerosol delivered also decreases. The applicant also surprisingly found that 0.5 mm 2 Below 5 mm, the amount of aerosol delivered decreased from the maximum amount. The applicant also found that, surprisingly, 2 For articles with an inlet area exceeding 5 mm, we found that the resulting amount of delivered aerosol decreased from the maximum amount. In some embodiments, the inlet opening was 5 mm 2 The following area, for example, 4mm 2 Below, 3mm 2Below, 2.61mm 2 Below, 1.91mm 2 Below, 1.21mm 2 Below, 0.86mm 2 It may have the following area:

[0058] Figure 7A shows graphs of the mass of aerosol delivered per puff, plotted for various articles with different outlet areas. Table 1 below shows the parameters for the various articles plotted in Figure 7A.

[0059] [Table 1]

[0060] The structures of the various items shown in Figure 7A are shown in Figure 8. Sub1: First substrate to which aerosol gel is attached, Sub2: Second substrate to which aerosol gel is attached, 1 / 1a / 1b: First intermediate layer, 2 / 2a / 2b: Second intermediate layer, 3 / 3a / 3b / 3c: Third intermediate layer.

[0061] In some articles, each of the first and second intermediate layers is made from two distinct flat components. In some articles, the third intermediate layer is made from three distinct flat components. In some articles, the conduit tapers toward the inlet opening. In some articles, the conduit tapers toward the outlet opening. In some articles, the conduit tapers longitudinally from the outlet opening to the inlet opening. In these articles, the thickness of the layers is substantially constant. In these articles, the inlet area is constant.

[0062] Figure 7A shows that articles with larger outlet openings can deliver a greater mass of aerosol compared to articles with smaller outlet openings. Specifically, A2, A3, and A5 produce the largest amounts of aerosol compared to the other articles in Figure 7A. Furthermore, Figure 7A shows that larger outlet openings can result in an increased amount of aerosol delivered, regardless of various differences in the structure of the articles, for example, varying degrees of tapering of the conduit. This may be due to larger outlet openings reducing turbulence and / or mixing of the airflow exiting the airflow path through the outlet opening. Therefore, larger outlet openings may tend to reduce the likelihood of aerosols separating from the airflow before delivery to the user. In addition, corners in the airflow path can trap a certain amount of aerosol. Larger outlet openings tend to reduce the size of these corners, thereby reducing the amount of aerosol that can be trapped in the airflow path.

[0063] At least 2.55 mm 2 An outlet opening with an area of, for example, 2.55 mm 2 Compared to articles with outlet openings having an area of ​​less than 6.85 mm, the mass of aerosols generated and / or delivered tends to be greater. In particular, when substantially 6.85 mm 2 An outlet opening having an area of ​​0.15 mm can particularly increase the amount of aerosol generated and / or the amount of aerosol delivered to the user. The outlet opening may be defined by the thickness of the third intermediate layer and the adhesive used to bond the third intermediate layer to the first and / or second intermediate layers. Additionally or alternatively, the outlet opening may be defined by the thickness of the first and / or second intermediate layers. In some embodiments, the outlet opening is 0.15 mm 2 Areas above, for example, 0.25 mm² 2 Above, 0.5mm 2 Above, 0.75mm 2 Above, 1.0 mm 2 1.25mm or more 2 Above, 1.5mm 2 Above, 1.75mm 2Above, 2.0mm 2 2.25mm or more 2 Above, 2.55mm 2 Above, 2.8mm 2 or more, 3mm 2 or more, 4mm 2 Above 5mm 2 or more, or 7mm 2 or more, or 9mm 2 or more, or 10mm 2 It may have an area greater than the above. In some embodiments, the outlet opening is 10 mm 2 The following area, for example, 9mm 2 The following, or 8mm 2 The following, or 7mm 2 The following, or 6mm 2 The following, or 5mm 2 The following, or 4.11mm 2 It may have the following area:

[0064] Referring to Figure 7B, this figure shows a graph plotting the amount of aerosol delivered for various articles with increasing outlet area. All the articles in Figure 7B have the same fixed inlet area. From Figure 7B, the amount of aerosol delivered increases with increasing outlet area of ​​4.11 mm². 2 It can be seen that even if it is increased by a larger amount, it does not change significantly.

[0065] In this embodiment, in the article tested with the experimental apparatus shown in Figure 8, the outlet opening and / or inlet opening are rectangular. Therefore, the area of ​​the outlet opening and / or inlet may be equal to the width w of the opening multiplied by the thickness of the third intermediate layer. The area of ​​the inlet and / or outlet may also be based on the shape of the inlet and / or outlet. In some embodiments, the inlet and / or outlet openings are not rectangular; for example, the inlet and / or outlet may be circular. In some embodiments, the area of ​​the outlet and / or inlet opening is determined by the thickness of one or more intermediate layers. In some embodiments, the area of ​​the outlet and / or inlet opening is not determined by the thickness of one or more intermediate layers; for example, the inlet and / or outlet opening may be drilled, perforated, or laser-cut in the intermediate layer. Advantageously, drilling the inlet opening can help spread the inlet airflow over the first and / or second aerosol-generating material. In some embodiments, there are multiple inlet openings at the distal end. In some embodiments, the inlet opening is substantially 0.88 mm 2 or 1.76mm 2It may have an area of ​​. In some embodiments, adjusting the pressure drop by 70 to 90 mmWG is particularly beneficial for the user experience. In this embodiment, the inlet and / or outlet are formed in the third intermediate layer. In other embodiments, the inlet and / or outlet are not formed in the third intermediate layer, and for example, the inlet and / or outlet may be formed in any one of the first intermediate layer, the second intermediate layer, the first substrate and the second substrate. In this embodiment, the intermediate layer is separate from the first and / or second substrate. In other embodiments, the intermediate layer is not separate from the first and / or second substrate, and for example, the intermediate layer may be formed integrally with the first and / or second substrate. In this embodiment, the third intermediate layer is formed integrally. In other embodiments, the third intermediate layer is not formed integrally, and for example, the third intermediate layer may be formed from a plurality of distinct components. In this embodiment, the third intermediate layer is flat. In other embodiments, the third intermediate layer is not flat. In this embodiment, the bridge section is positioned so as not to overlap the first and second aerosol-generating materials. In other embodiments, the bridge section is positioned so as to at least partially overlap the first and / or second aerosol-generating materials.

[0066] In some embodiments, the airflow path may be substantially free of obstructions. Ensuring that the airflow path is as free of obstructions as possible may be beneficial to the performance of the article, for example, to achieve a specific pressure drop and / or a specific aerosol mass for delivery. An obstruction-free airflow path may not have any structures located within the airflow path adjacent to the aerosol-generating material. In other words, there is nothing within the airflow path that can alter the trajectory of the air flowing in the airflow path near the aerosol-generating material. It should be noted that embodiments in which the airflow path is obstruction-free may coincide with embodiments that have a flow control feature located at the inlet and / or a flow control feature located at a bridge provided in a third intermediate layer. In other words, some embodiments may have both an obstruction-free airflow path and a flow control feature located at the inlet opening. The airflow path may be considered to be downstream of the inlet opening. Furthermore, the article including the intermediate layer in Figure 5A may be considered obstruction-free because there are no obstructions in the aerosol-generating material. Specifically, because the bridging section and / or flow control feature section are offset from and / or do not overlap with the aerosol-generating material, the aerosol flow is not obstructed or altered by the bridging section and / or flow control feature section.

[0067] Figure 9 shows graphs of the delivered aerosol mass plotted for various articles, obtained from experimental testing of the designed articles. The articles either include ribs in the airflow path or not. Table 2 below shows the parameters for the various articles plotted in Figure 9.

[0068] [Table 2]

[0069] Figure 10 shows the structures of various items shown in Figure 9. Sub1: First substrate to which aerosol gel is attached, Sub2: Second substrate to which aerosol gel is attached, 1 / 1a / 1b: First intermediate layer, 2 / 2a / 2b: Second intermediate layer, 3 / 3a / 3b / 3c: Third intermediate layer.

[0070] In some articles, each of the first and second intermediate layers is made from two separate flat components. In some articles, the third intermediate layer is made from three separate flat components. In some articles, the conduit tapers toward the inlet opening. In some articles, the conduit tapers toward the outlet opening. In some articles, the conduit tapers longitudinally from the outlet opening to the inlet opening. The ribs shown in Figure 10 and Table 2 may be considered as one or more of the aforementioned transverse members extending across the width of the intermediate layer and / or conduit.

[0071] As can be seen from Figure 9, articles without obstructions generally deliver a larger mass of aerosol compared to articles with obstructions. Specifically, A9, A10, and A13 show that the absence of obstructions in the airflow path allows for the delivery of more aerosol compared to articles with ribs (A8, A11, and A12). This further suggests that the inlet area can achieve pressure drop adjustment without significantly affecting other performance factors. In these embodiments, the airflow path is substantially obstruct-free. However, in other embodiments, the airflow path includes obstructions.

[0072] Referring to Figure 11, article 110, in its fully assembled state, comprises a first substrate 302 on top of a first intermediate layer 502. The first aerosol-generating material 306 is shown by a dashed line extending from the bottom surface of the first substrate 302 through the first intermediate layer 502 to the bottom surface of the first intermediate layer 502. In some embodiments, the first aerosol-generating material 306 may extend beyond the bottom surface of the first intermediate layer 502. The first intermediate layer 502 is placed on top of a third intermediate layer 506. The third intermediate layer 506 is placed on top of a second intermediate layer 504. The second intermediate layer 504 is placed on top of a second substrate 304. The second aerosol-generating material 308 is shown by a dashed line extending from the top surface of the second substrate 304 through the second intermediate layer 504 to the top surface of the second intermediate layer 504.

[0073] The first intermediate layer 502, the first aerosol-generating material 306, the third intermediate layer 506, the second intermediate layer 504, and the second aerosol-generating material 308 work together to form a passage that fluidly connects the inlet opening 508 to the outlet opening 510. The first intermediate layer 502, the first aerosol-generating material 306, the second intermediate layer 504, and the second aerosol-generating material 308 can be considered to surround the conduit of the third intermediate layer 506, thereby forming the passage. The first and / or second aerosol-generating materials 306, 308 can be activated to generate aerosols in the passage and / or conduit. The passage and / or conduit may be considered an airflow path.

[0074] In this embodiment, the passage is formed by a first intermediate layer, a first aerosol-generating material, a third intermediate layer, a second intermediate layer, and a second aerosol-generating material. In other embodiments, the cavity is not formed by a first intermediate layer, a first aerosol-generating material, a third intermediate layer, a second intermediate layer, and a second aerosol-generating material; for example, the passage may be formed by one or more of the first intermediate layer, the first aerosol-generating material, the third intermediate layer, the second intermediate layer, and the second aerosol-generating material.

[0075] 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 or modified without departing from the scope of the claimed invention. Various embodiments of the invention may appropriately include, consist of, or be essentially composed of, appropriate combinations of disclosed elements, components, features, parts, processes, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. Aerosol-forming article, A first surface containing an aerosol-generating material, The second surface facing the first surface and the first surface are arranged such that an airflow path is defined between the first surface and the second surface, An inlet that allows air to flow into the aerosol-forming article between the first surface and the second surface, Equipped with, The aforementioned entrance is at least 0.15 mm ２ An aerosol-forming article having the area of ​​[specified area].

2. The aforementioned entrance is at least 0.25 mm ２ An aerosol-forming article according to claim 1, having the area of ​​the above.

3. The aforementioned entrance is at least 0.37 mm ２ An aerosol-forming article according to claim 2, having the area of ​​the above.

4. The aforementioned entrance is at least 0.45 mm ２ An aerosol-forming article according to claim 3, having the area of ​​the above.

5. The aforementioned entrance is substantially 0.51 mm ２ An aerosol-forming article according to claim 4, having the area of ​​the above.

6. The aerosol-forming article according to any one of claims 1 to 5, wherein the aerosol-forming article is formed from a layered structure, and the layered structure comprises a first layer defining the first surface and a second layer defining the second surface.

7. The aerosol-forming article according to claim 6, wherein the layered structure is a layered structure that has been bent.

8. The aerosol-forming article according to any one of claims 1 to 7, wherein the layered structure comprises an intermediate layer, and the inlet is formed in the intermediate layer.

9. The aerosol-forming article according to any one of claims 1 to 8, further comprising a flow control feature portion, wherein the air from the inlet is arranged to collide with the flow control feature portion, and the flow control feature portion is configured to reduce the velocity of the air.

10. The aerosol-forming article according to claim 9, wherein the flow control feature portion is formed by a transverse member.

11. The aerosol-forming article according to claim 9 or 10, wherein the flow control feature portion is formed in the intermediate layer.

12. The aerosol-forming article according to any one of claims 9 to 11, wherein the flow control feature is located upstream of the aerosol-generating material.

13. The aerosol-forming article according to any one of claims 1 to 12, wherein the inlet is formed by removing a portion of the intermediate layer.

14. The aerosol-forming article according to any one of claims 1 to 13, wherein the layered structure further comprises a further intermediate layer between the intermediate layer and the first layer.

15. The aerosol-forming article according to any one of claims 1 to 14, wherein the layered structure further comprises an additional intermediate layer between the intermediate layer and the second layer.

16. The aerosol-forming article according to any one of claims 1 to 15, wherein the airflow path does not contain any obstructions between the first surface and the second surface at the location of the aerosol-generating material.

17. The aerosol-forming article according to any one of claims 1 to 16, wherein the second surface comprises an aerosol-generating material.

18. The aerosol-forming article according to any one of claims 1 to 17, wherein the first surface is substantially flat.

19. The aerosol-forming article according to any one of claims 1 to 18, wherein the second surface is substantially flat.

20. an aerosol-forming article according to any one of claims 1 to 19, an aerosol supply device configured to generate an aerosol by heating the aerosol generating material, An aerosol supply system equipped with the following features.

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