Assembly for an aerosol delivery device

Abstract

Disclosed herein is an assembly (100) for an aerosol delivery device (1) for heating an aerosol generating material to volatilize at least one component of the aerosol generating material. The assembly (100) comprises a heating zone for receiving the aerosol generating material to be heated, a structure, and at least one continuous conductive path supported by the structure configured to perform a first function of detecting a temperature of the heating zone based on an electrical resistance of the at least one path and / or a second function of heating the heating zone by resistive heating. The at least one path extends along at least two distinct portions of the structure. The at least one path comprises multiple turns in each of the at least two distinct portions of the structure. The at least two distinct portions of the structure are offset from one another by a gap that is substantially free of the at least one path.

Description

[Technical field]

[0001] The present invention relates to an assembly for an aerosol delivery device, an aerosol delivery device and an aerosol delivery system comprising an aerosol delivery device for generating an inhalable medium by heating an aerosol generating substance to volatilize at least one component of the aerosol generating substance. [Background technology]

[0002] (background) Smoking articles, such as cigarettes and cigars, burn tobacco during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without burning. Examples of such products are so-called "non-combustion heat-to-burn" products or tobacco heating devices or products that do not burn a substance but release compounds by heating it. The substance may be, for example, a tobacco product or other non-tobacco product that may or may not contain nicotine. Summary of the Invention

[0003] (overview) A first aspect of the present invention provides an assembly for an aerosol delivery device for heating an aerosol generating material to volatilize at least one component of the aerosol generating material, the assembly comprising: a heating zone for receiving the aerosol generating material to be heated; a structure; and at least one continuous conductive path supported by the structure configured to perform a first function of detecting a temperature of the heating zone based on an electrical resistance of the at least one path and / or a second function of heating the heating zone by resistive heating, wherein the at least one path extends along at least two separate portions of the structure, the at least one path comprises multiple turns in each of the at least two separate portions of the structure, and the at least two separate portions of the structure are offset from one another by a gap that is substantially free of the at least one path.

[0004] In some embodiments, the gap extends in an extension direction, the extension direction corresponding to a direction away from the longitudinal direction of the heating zone, hi some embodiments, the extension direction is perpendicular to the longitudinal direction of the heating zone.

[0005] In some embodiments, the gap follows a pathway that is arcuate, hi some embodiments, the pathway is a circumferential pathway that extends at least partially around the heating zone.

[0006] In some embodiments, the gap extends along a first plane and the longitudinal axis of the heating zone extends along a second plane, the first plane being orthogonal to the second plane.

[0007] In some embodiments, at least one pathway comprises a single portion within the gap. In some embodiments, the single portion is a connecting portion that extends across the gap to connect at least two separate portions of the structure. In some embodiments, the single portion extends across the width of the gap.

[0008] In some embodiments, a portion of at least one path in the gap occupies less than 10% of the area of ​​the gap, hi some embodiments, the portion occupies less than 5% of the area of ​​the gap.

[0009] In some embodiments, at least two portions of the structure are distinguishable by the size of the gap relative to the size of the spacing between adjacent portions of at least one path within each of the two portions of the structure.

[0010] In some embodiments, the dimension of the gap in the first direction is greater than the distance in the first direction from one of the multiple turns to an adjacent one of the multiple turns. In some embodiments, the dimension of the gap in the second direction is less than the distance from one of the multiple turns to an adjacent one of the multiple turns. In some embodiments, the first direction is orthogonal to the second direction.

[0011] In some embodiments, each portion has at least one repeating pattern.

[0012] In some embodiments, at least one path occupies at least 40% of the area of ​​the structure in at least one of the two distinct portions, hi some embodiments, at least one path occupies between 40% and 60% of the area of ​​the structure in at least one of the two distinct portions.

[0013] In some embodiments, at least one passage surrounds the heating zone. In some embodiments, at least one passage forms a single layer. In some embodiments, the single layer has a circular cross-section.

[0014] In some embodiments, adjacent edges of at least one path are closer to each other within each of the at least two separate portions of the structure compared to adjacent edges of at least one path between the at least two separate portions of the structure.

[0015] In some embodiments, at least one of the paths comprises multiple straight sections within at least two separate portions of each of the structures, each straight section being interconnected by two turns of the multiple turns. In some embodiments, the main portions of the straight sections are parallel to each other. In some embodiments, adjacent straight sections of the multiple straight sections are spaced from each other by a gap of a size smaller than the gap. In some embodiments, the gap is less than twice the width of each straight section. In some embodiments, the gap is less than twice the width of each straight section. In some embodiments, the gap is between 50% and 200% of the width of each straight section. In some embodiments, the gap is between 50% and 150% of the width of each straight section. In some embodiments, any one of the multiple straight sections extends only partially around the heating zone. In some embodiments, any one of the multiple straight sections extends only partially along the heating zone. In some embodiments, the maximum length of any one of the multiple straight sections of the at least one path is greater than the maximum length of any one of the multiple straight sections.

[0016] In some embodiments, each distinct portion comprises a boundary of at least two portions that is linear. In some embodiments, the boundary has a shape corresponding to a polygon. In some embodiments, the polygon is a quadrilateral. In some embodiments, the quadrilateral is a square or a rectangle. In some embodiments, the direction of each boundary line is tangent to one turn of the multiple turns. In some embodiments, the direction of each boundary line is parallel or perpendicular to one of the multiple straight portions. In some embodiments, the direction of each boundary line is tangent to any one turn of the multiple turns or parallel to any one of the multiple straight portions.

[0017] In some embodiments, a first spacing between adjacent portions of the at least one path within the region of the gap is greater than a second spacing between adjacent portions of the at least one path outside the region of the gap.

[0018] In some embodiments, the gap extends to at least one turn of the multiplicity of turns in at least two separate portions of each of the structures, hi some embodiments, the gap extends to multiple turns of the multiplicity of turns in at least two separate portions of each of the structures.

[0019] In some embodiments, at least two separate portions of the structure are arranged relative to each other in a longitudinal direction of the heating zone, hi some embodiments, each separate portion of the structure is arranged relative to each other one of the separate portions in a longitudinal direction of the heating zone or in a direction perpendicular to the longitudinal direction of the heating zone.

[0020] In some embodiments, each one of the multiple turns is arcuate, i.e., each one of the turns is not square, to reduce mechanical stress on the one turn. In some embodiments, each one of the multiple turns is circular. In some embodiments, each one of the multiple turns is circular.

[0021] In some embodiments, the radius of each one of the multiple turns is greater than the thickness of at least one path. In some embodiments, the radius of each one of the multiple turns is at least 110% of the thickness of at least one path. In some embodiments, the radius of each one of the multiple turns is at least 125% of the thickness of at least one path. In some embodiments, the radius of each one of the multiple turns is between 110% and 190% of the thickness of at least one path. In some embodiments, the radius of each one of the multiple turns is between 125% and 175% of the thickness of at least one path.

[0022] In some embodiments, a first width of at least one path within at least one of the multiple turns is greater than a second width of at least one path outside of at least one of the multiple turns. In some embodiments, the second width is the width of one of the straight sections. In some embodiments, the first width is at least 25% greater than the second width. In some embodiments, the first width is the width of a turn greater than 90 degrees and is at least 50% greater than the second width. In some embodiments, the width of at least one path within at least one of the multiple turns varies within the turn. In some embodiments, the width of at least one path within at least one of the multiple turns increases towards a midpoint of the turn.

[0023] In some embodiments, the width of at least one path within a 180 degree turn is greater than the width of at least one path within a 90 degree turn. In some embodiments, the width of at least one path within a 90 degree turn is between 75% and 95% of the width of at least one path within a 180 degree turn. In some embodiments, the width of at least one path within a 90 degree turn is between 80% and 90% of the width of at least one path within a 180 degree turn.

[0024] In some embodiments, at least one path comprises a stress relief structure comprising a first turn in a first direction followed by a second turn in a second direction, and the length of at least one path between the first turn and the second turn is less than the length of one of the first turn and the second turn. In some embodiments, the length of at least one path between the first turn and the second turn is less than the length of both the first turn and the second turn. In some embodiments, the stress relief structure comprises a third turn in the first direction. In some embodiments, the length of at least one path between the second turn and the third turn is less than the length of one of the first turn, the second turn, and the third turn. In some embodiments, the length of at least one path between the second turn and the third turn is less than the length of any of the first turn, the second turn, and the third turn. In some embodiments, the length of at least one path between the first turn and the second turn is equal to the length of at least one path between the second turn and the third turn. In some embodiments, the length of at least one path between the first turn and the second turn and between the second turn and the third turn is negligible compared to the length of one of the first turn, the second turn, and the third turn. In some embodiments, at least one turn from the first turn to the third turn is a 180 degree turn. In some embodiments, the second turn is a 180 degree turn. In some embodiments, two turns from the first turn to the third turn are 90 degree turns. In some embodiments, at least one turn from the first turn to the third turn is a 180 degree turn.

[0025] In some embodiments, at least one pathway comprises a connecting portion that extends across the gap to connect at least two separate portions of the structure. In some embodiments, the connecting portion extends across the gap at one end of the at least two separate portions of the structure. In some embodiments, the connecting portion comprises one turn of many turns. In some embodiments, the connecting portion comprises an inward turn that faces toward the center of the gap. In some embodiments, the center of the gap is referenced to the length of the gap. In some embodiments, the connecting portion comprises an outward turn that faces away from the center of the gap. In some embodiments, the connecting portion additionally comprises a stress relief structure. In some embodiments, the connecting portion can perform the first and / or second functions to a lesser extent than other portions of the at least one pathway within each of the at least two separate portions of the structure.

[0026] In some embodiments, the multiple turns comprise a major turn and a minor turn, the major turn and the minor turn having different angles of rotation (measured in degrees) about a central axis of rotation. In some embodiments, the major turn is at least 45 degrees greater than the minor turn. In some embodiments, the major turn is at least 90 degrees greater than the minor turn. In some embodiments, the major turn has an angle of rotation between 45 degrees and 135 degrees greater than the angle of rotation of the minor turn. In some embodiments, the multiple turns comprise at least one 180 degree turn. In some embodiments, the multiple turns comprise at least one 90 degree turn. In some embodiments, the main portion of the multiple turns is a 180 degree turn.

[0027] In some embodiments, the multiple turns comprise at least one semicircular turn. In some embodiments, a main portion of the multiple turns comprises a semicircular turn. In some embodiments, the multiple turns comprise at least one quarter-circular turn. In some embodiments, a main portion of the multiple turns comprises a quarter-circular turn.

[0028] In some embodiments, at least one path comprises a first portion and a second portion that extend to and traverse different respective sides of one of the at least two distinct portions of the structure.

[0029] In some embodiments, the number of turns per unit length of at least one path within one of the at least two distinct portions of the structure is different in one region of the at least two distinct portions of the structure compared to another region of the at least two distinct portions of the structure.

[0030] In some embodiments, at least one pathway extends side-to-side from one end to another within at least two separate portions of each of the structures.

[0031] In some embodiments, the multiple turns in each at least one path form separate row arrays in at least two separate portions of the structure and columns in at least two separate portions. In some embodiments, the arrays comprise multiple straight sections. In some embodiments, the rows are primarily formed by multiple straight sections joined by multiple turns. In some embodiments, the straight sections extend longitudinally through the heating zone.

[0032] In some embodiments, the heating zone has a cross-section having a shape corresponding to a regular polygon. In some embodiments, the cross-sectional shape is an arc. In some embodiments, the cross-sectional shape corresponds to a circle.

[0033] In some embodiments, the structure is or comprises at least one electrically insulating element, and the at least one continuous conductive path is a continuous conductive wire encapsulated by at least one electrically insulating element. In some embodiments, the wire has a circular cross-section. In some embodiments, the wire has a circular cross-section along substantially the entire length of the wire.

[0034] In some embodiments, the assembly comprises a plurality of continuous conductive paths, each of the first and second paths of the plurality of continuous conductive paths extending along at least two separate portions of the structure in respective first and second regions, the first and second regions being offset from each other by a gap that does not include any of the plurality of paths. In some embodiments, the first and second regions are offset from each other in a longitudinal direction of the assembly. In some embodiments, the first and second regions are offset from each other in a longitudinal direction of the heating zone. In some embodiments, the longitudinal direction of the heating zone is parallel to the longitudinal direction of the assembly.

[0035] In some embodiments, the second path is a substantial mirror image of the first path about an imaginary line between the first and second paths, hi some embodiments, the width of the first region is substantially equal to the width of the second region.

[0036] In some embodiments, the heating zone comprises a first heating zone and a second heating zone, and a first path in the first zone is for performing a first and / or second function associated with the first heating zone and a second path in the second zone is for performing a first and / or second function associated with the second heating zone, hi some embodiments, the second path in the second zone is for performing the same function as the first path in the first zone.

[0037] In some embodiments, multiple paths are supported by the same side of the structure.

[0038] In some embodiments, the structure is or comprises at least one electrically insulating element, and at least one continuous conductive path of the plurality of continuous conductive paths is a continuous conductive wire encapsulated by at least one electrically insulating element. In some embodiments, the wire has a circular cross-section. In some embodiments, the wire has a circular cross-section along substantially the entire length of the wire.

[0039] In some embodiments, the structure is or comprises an electrically insulating substrate, and the at least one continuous conductive pathway is a continuous conductive track formed on the electrically insulating substrate.

[0040] In some embodiments, an assembly comprises a plurality of structures provided as a plurality of structural layers, and a plurality of continuous conductive paths, at least one continuous conductive path of the plurality of continuous conductive paths being supported by a respective one of the plurality of structural layers, and each of the plurality of paths being for performing a different one of the first and second functions.

[0041] In some embodiments, each of the at least one path extends along at least two distinct portions of each of the plurality of structures within individual regions, each of the regions overlapping one another.

[0042] In some embodiments, an assembly comprises a plurality of structures provided as a plurality of structural layers, and a plurality of continuous conductive paths supported by a respective one of the plurality of structural layers, where a first path and a second path of the plurality of continuous conductive paths are each supported by a first structural layer, and a third path and a fourth path of the plurality of continuous conductive paths are each supported by a second structural layer, each of the first through fourth paths extending along at least two separate portions of the respective structures within respective first to fourth regions, and each of the first and second regions on the first structural layer overlaps at least one of the third and fourth regions on the second structural layer.

[0043] In some embodiments, each of the plurality of structural layers is for performing a different one of the first and second functions.

[0044] In some embodiments, any restriction defined with respect to one of the paths also applies to any one or any combination of the other paths, for example, in some embodiments, one path extends from one end to another end side-to-side within at least two separate portions of each of the first structures.

[0045] In some embodiments, any limitation defined with respect to at least two portions of one of the structures also applies to any one portion or any combination of the at least two portions of the other structures.

[0046] In some embodiments, the length of the first path is less than 0.5 m. In some embodiments, the length of the first path is between 0.2 m and 0.4 m. In some embodiments, the length of the first path is between 0.3 m and 0.35 m. In some embodiments, the length of the first path is 333.85 mm.

[0047] In some embodiments, the length of the second path is less than 0.5 m. In some embodiments, the length of the second path is between 0.2 m and 0.4 m. In some embodiments, the length of the second path is between 0.3 m and 0.35 m. In some embodiments, the length of the second path is 328.95 mm.

[0048] In some embodiments, the length of the second path is between 90% and 110% of the length of the first path. In some embodiments, the length of the second path is between 95% and 105% of the length of the first path. In some embodiments, the length of the second path differs from the length of the first path by no more than 10 mm. In some embodiments, the length of the second path differs from the length of the first path by no more than 5 mm. In some embodiments, the difference between the length of the second path and the length of the first path is less than or equal to 5%. In some embodiments, the difference between the length of the second path and the length of the first path is less than or equal to 3%.

[0049] In some embodiments, the thickness of at least one passage is less than 1 mm. In some embodiments, the thickness of at least one passage is less than 0.1 mm. In some embodiments, the thickness of at least one passage is between 40 μm and 60 μm. In some embodiments, the thickness of at least one passage is 50.8 μm (0.0508 mm).

[0050] In some embodiments, the thickness of the second passage is between 90% and 110% of the thickness of the first passage. In some embodiments, the thickness of the second passage is between 95% and 105% of the thickness of the first passage. In some embodiments, the thickness of the second passage differs from the thickness of the first passage by no more than 10 μm. In some embodiments, the thickness of the second passage differs from the thickness of the first passage by no more than 5 μm. In some embodiments, the thickness of the second passage is equal to the thickness of the first passage.

[0051] In some embodiments, the width of at least one pathway is less than 1 mm. In some embodiments, the width of at least one pathway is less than 0.6 mm. In some embodiments, the width of at least one pathway is between 0.2 mm and 0.6 mm. In some embodiments, the width of at least one pathway is between 0.3 mm and 0.4 mm. In some embodiments, the width of at least one pathway is 0.3175 mm.

[0052] In some embodiments, the main width of at least one path is less than 1 mm. In some embodiments, the main width of at least one path is less than 0.5 mm. In some embodiments, the main width of at least one path is between 0.2 mm and 0.4 mm. In some embodiments, the main width refers to the average width of the entire path. In other embodiments, the main width refers to the average width of multiple straight portions of at least one path.

[0053] In some embodiments, the main width of the second path is between 90% and 110% of the main width of the first path. In some embodiments, the main width refers to the average width of the entire path. In other embodiments, the main width refers to the average width of multiple straight portions of the path. In some embodiments, the main width of the second path is between 95% and 105% of the main width of the first path. In some embodiments, the main width of the second path is equal to the main width of the first path.

[0054] In some embodiments, any one or all of the plurality of structures are provided outside the heating zone.

[0055] In some embodiments, any one of the at least one pathway is made of a metallic material, such as copper.

[0056] In some embodiments, at least one structure of the plurality of structures is or comprises an electrically insulating substrate, and at least one path of the plurality of paths is a continuous conductive track formed on the electrically insulating substrate.

[0057] In some embodiments, at least one structure of the plurality of structures is or comprises at least one electrically insulating element, and at least one continuous conductive path of the plurality of continuous conductive paths is a continuous conductive wire encapsulated by at least one electrically insulating element. That is, at least one structure of the plurality of structures is or comprises an electrically insulating element. In some embodiments, the wire has a circular cross-section. In some embodiments, the wire has a circular cross-section along substantially the entire length of the wire.

[0058] In some embodiments, at least one continuous conductive pathway has a first electrical resistance under predetermined conditions configured to perform a first function that is lower than a second electrical resistance configured to perform a second function. In some embodiments, the predetermined conditions include a temperature and / or a voltage across the at least one continuous conductive pathway. In some embodiments, the second electrical resistance is at least twice the first electrical resistance. In some embodiments, the second electrical resistance is between 2 and 5 times the first electrical resistance. In some embodiments, the second electrical resistance is between 3 and 4 times the first electrical resistance.

[0059] In some embodiments, the term "multiple" means a plurality.

[0060] A second aspect of the present invention provides an aerosol delivery device for heating an aerosol generating substance to volatilize at least one component of the aerosol generating substance, the device comprising an assembly according to the first aspect, a control device for controlling the supply of power from a power source to at least one continuous conductive path of the assembly, and a detection device for detecting the electrical resistance of the at least one path.

[0061] In some embodiments, the electrical resistance can be detected periodically by a detection device.

[0062] In some embodiments, the controller is for converting the electrical resistance of the at least one pathway into a temperature measurement of the at least one pathway. In some embodiments, at least one first connecting pathway connects the at least one pathway to the controller, the at least one first connecting pathway being less sensitive to temperature changes in the heating zone compared to the at least one pathway. In some embodiments, the temperature sensitivity of the at least one first connecting pathway is governed by a position of the at least one first connecting pathway relative to the heating zone. In some embodiments, a length of the at least one first connecting pathway is disposed in a longitudinal direction of the heating zone in a direction away from the heating zone. In some embodiments, the temperature measurement accounts for the resistance of the first connecting pathway using predetermined information regarding the at least one pathway and the first connecting pathway. In some embodiments, the predetermined information includes geometric information regarding the at least one pathway and the first connecting pathway. In some embodiments, the geometric information includes a length of the at least one pathway and a length of the first connecting pathway. In some embodiments, the geometric information includes a thickness and / or width of the at least one pathway and a thickness and / or width of the first connecting pathway. In some embodiments, at least one second connection path connects the second path to the controller, and the at least one second connection path is less susceptible to temperature changes in the heating zone compared to the second path, in some embodiments, a temperature measurement associated with the at least one path accounts for the resistance of the second path and / or the at least one second connection path.

[0063] A third aspect of the invention provides an aerosol delivery system comprising an aerosol delivery device according to the second aspect and a consumable containing an aerosol generating substance, the consumable being insertable into a heating zone of an assembly of the device.

[0064] A fourth aspect of the present invention provides a method for detecting the temperature of a heating zone for receiving an aerosol generating material to be heated, the method comprising: controlling the supply of power from a power source to at least one conductive path by a control device; detecting an electrical resistance of the at least one conductive path by a detection device; detecting an electrical resistance of a portion of the at least one conductive path away from the heating zone based on predetermined information about the portion by the detection device; and calculating the temperature of the heating zone based on the electrical resistance of the at least one conductive path and the electrical resistance of the portion of the track away from the heating zone.

[0065] In some embodiments, the method includes sampling the electrical resistance of the path for a predetermined duration. In some embodiments, the predetermined duration is about 250 μs. In some embodiments, the predetermined duration is between 0.1 ms and 0.4 ms.

[0066] In some embodiments, the heating zone described above in relation to the fourth aspect is included in the assembly described above in relation to the first aspect.

[0067] In some embodiments, at least one conductive pathway as described above in relation to the fourth aspect comprises any feature of the conductive pathway as described above in relation to the first aspect.

[0068] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0069] [Figure 1] FIG. 1 is a schematic perspective view of an aerosol delivery system including an aerosol delivery device according to an embodiment of the present invention, with a consumable containing an aerosol generating material inserted therein, the device being for heating the aerosol generating material of the consumable to volatilize at least one component of the aerosol generating material. [Diagram 2]2 is a schematic cross-sectional front view of an aerosol delivery device of the aerosol delivery system of FIG. 1 without a consumable inserted therein, according to an embodiment of the present invention; [Diagram 3] FIG. 3 is a first schematic diagram showing an assembly for the device of FIG. 2 according to an embodiment of the present invention. [Figure 4] FIG. 4 is a second schematic diagram illustrating the assembly shown in FIG. 3 for the device of FIG. 2 according to an embodiment of the present invention. [Figure 4A] 3 is a schematic cross-sectional view showing an alternative assembly for the device of FIG. 2 according to another embodiment of the present invention. [Diagram 5] FIG. 3 is a schematic diagram showing an electrical structure with conductive tracks for the device of FIG. 2 according to an embodiment of the present invention. [Figure 6] FIG. 6 is a schematic enlarged view of one of the conductive tracks shown in FIG. 5 according to an embodiment of the present invention. [Figure 7] FIG. 7 is a schematic enlarged view showing an area of ​​the track shown in FIG. 6 according to an embodiment of the present invention. [Figure 8] 7 is a schematic enlarged view showing another area of ​​the track shown in FIG. 6 according to an embodiment of the present invention. [Figure 9] 7 is a schematic enlarged view showing another area of ​​the track shown in FIG. 6 according to an embodiment of the present invention. [Figure 10] 7 is a schematic enlarged view showing a first separate portion of the track shown in FIG. 6 according to an embodiment of the present invention. FIG. [Figure 11] FIG. 11 is a schematic enlarged view showing an area of ​​the track shown in FIG. 10 with a 180 degree turn according to an embodiment of the present invention. [Figure 12] 7 is a schematic enlarged view showing a second separate portion of the track shown in FIG. 6 according to an embodiment of the present invention. FIG. [Figure 13] FIG. 7 is a schematic enlarged view showing a third separate portion of the track shown in FIG. 6 according to an embodiment of the present invention. [Figure 14] FIG. 13 is a schematic enlarged view showing an area of ​​the track shown in FIG. 12 with a 90 degree turn according to an embodiment of the present invention. [Figure 15] FIG. 6 is a schematic diagram showing another electrical structure with conductive tracks for the device of FIG. 2 to be superimposed on the electrical structure of FIG. 5 according to an embodiment of the present invention. [Figure 16] FIG. 3 is a schematic cross-sectional view showing an assembly comprising substrate layers according to an embodiment of the invention, each substrate comprising conductive tracks for the device of FIG. 2. [Figure 17] FIG. 16 is a schematic diagram illustrating another electrical configuration shown in FIG. 15 comprising conductive tracks for the device of FIG. 2 according to an embodiment of the invention. [Figure 18] FIG. 18 is a schematic enlarged view of one of the conductive tracks shown in FIG. 17 according to an embodiment of the present invention. [Figure 19] FIG. 2 shows an electrical circuit for measuring the resistance of the first track. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0070] (Detailed Description) The present disclosure relates to aerosol delivery devices, such as non-combustible aerosol delivery devices. According to the present disclosure, a "non-combustible" aerosol delivery device is one in which the component aerosol generating material contained in a consumable for receipt by the chamber (or a component thereof) of the aerosol delivery device is not burned or combusted to facilitate delivery of the aerosol generating material to a user.

[0071] The term "aerosol generating material" as used herein includes a material that upon heating provides volatile components, typically in the form of a vapor or an aerosol. The aerosol generating material may be a non-tobacco-containing material or a tobacco-containing material. The aerosol generating material may include, for example, one or more of tobacco itself, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes. The aerosol generating material may be in the form of ground tobacco, cut rag tobacco, extruded tobacco, reconstituted tobacco, reconstituted aerosol generating material, liquid, gel, amorphous solid, gelled sheet, powder, or mass, etc. The aerosol generating material may further include other non-tobacco products that may or may not contain nicotine depending on the product. The aerosol generating material may comprise one or more humectants, such as glycerol or propylene glycol. The term "aerosol generating material" may also be used interchangeably herein with the term "aerosol-generating material".

[0072] The term "tobacco material" as used herein means any material that contains tobacco or a derivative thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material may include one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extracts.

[0073] The tobacco used to create the tobacco material may be any suitable tobacco, such as single grades or blends, cut rags or whole leaf, including Virginia, Burley, and / or Oriental. The tobacco material may also be tobacco particle "fine" or dust, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be ground tobacco or reconstituted tobacco material. Reconstituted tobacco material may include tobacco fiber and may be formed by casting, which is a Fourdrinier-based paper making-type approach with back addition of tobacco extract, or by extrusion.

[0074] As noted above, the aerosol generating material can include an amorphous solid, which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous) or a "dry gel." An amorphous solid is a solid material that can hold some fluid, such as a liquid, within it. In some cases, the aerosol generating material includes about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. In some cases, the aerosol generating material is composed of an amorphous solid.

[0075] The term "sheet" as used herein means an element that has a width and length that is significantly greater than its thickness. A sheet may be, for example, a strip.

[0076] The terms "heating material" or "heating device material" as used herein refer, in some embodiments, to a material that can be heated by the penetration of a variable magnetic field, for example when an aerosol generating material is heated by an induction heating arrangement.

[0077] Other forms of heating the heating substance include resistive heating, which involves an electrical resistive heating element that increases in temperature when an electric current is applied and transfers heat to the heating substance by conduction.

[0078] A susceptor is a material that is heatable by the penetration of a variable magnetic field, such as an alternating magnetic field. The susceptor can be a conductive material, such that the penetration of the variable magnetic field causes inductive heating of the heating material. The heating material can be a magnetic material, such that the penetration of the variable magnetic field causes magnetic hysteresis heating of the heating material. The susceptor can be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a variable magnetic field is referred to herein as a magnetic field generator.

[0079] It has been found that when the susceptor is in the form of a closed electrical circuit, the magnetic coupling between the susceptor and the electromagnet in use is enhanced, thereby increasing or improving Joule heating.

[0080] Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by subjecting the object to a variable magnetic field. A magnetic material can be thought of as containing many atomic-scale magnets or magnetic dipoles. When a magnetic field penetrates such a material, the orientation of the magnetic dipoles aligns with the magnetic field. Thus, when a variable magnetic field, for example an alternating magnetic field such as that produced by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the applied variable magnetic field. This change in orientation of the magnetic dipoles produces heat in the magnetic material.

[0081] If an object is both conductive and magnetic, then a variable magnetic field penetrating the object can cause both Joule and magnetic hysteresis heating within the object. Furthermore, the magnetic field can be made stronger by using magnetic materials, thereby enhancing Joule and magnetic hysteresis heating.

[0082] In each of the above processes, when heat is generated within the object itself, rather than by an external heat source through thermal conduction, a faster temperature rise and more uniform heat distribution within the object can be achieved, particularly by selecting the appropriate object material and geometry, and by selecting the appropriate variable magnetic field magnitude and orientation relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require the realization of a physical connection between the source of the variable magnetic field and the object, allowing for greater design freedom and control over the heating profile, and reducing costs.

[0083] In some embodiments, the aerosol delivery device is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (ENDS), although it should be noted that the presence of nicotine in the aerosol generating material is not a requirement.

[0084] In some embodiments, the aerosol delivery device is a tobacco heating device, also known as a non-combustion heating device.

[0085] In some embodiments, the aerosol delivery device is a hybrid device for generating an aerosol using a combination of aerosol generating materials, one or more of which can be heated. Each of the aerosol generating materials can be, for example, in solid, liquid, or gel form, and may or may not include nicotine. In some embodiments, the hybrid device includes a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material can include, for example, a tobacco product or a non-tobacco product.

[0086] In some embodiments, the aerosol delivery device can include a power source, which can be, for example, an electric power source.

[0087] In some embodiments, a consumable for use with an aerosol delivery device can include an aerosol generating component, an aerosol generating area, a mouthpiece, and / or an area for receiving an aerosol generating substance.

[0088] In some embodiments, the aerosol delivery device may comprise an aerosol generating component. The aerosol generating component is a heating device that may interact with the aerosol generating substance to release one or more volatile substances from the aerosol generating substance to form an aerosol. In some embodiments, the aerosol generating component may generate an aerosol from the aerosol generating substance without heating. For example, the aerosol generating component may be capable of generating an aerosol from the aerosol generating substance without applying heat to the aerosol generating substance, for example, via one or more of vibrational, mechanical, pressurized, or electrostatic means. In some embodiments, the aerosol generating component may form part of the aerosol delivery device.

[0089] In some embodiments, the substance to be delivered by the aerosol delivery device may be an aerosol generating material, which may include an active ingredient, a carrier ingredient, and optionally one or more other functional ingredients.

[0090] The active ingredient may include one or more physiological and / or olfactory active ingredients included in the aerosol generating material to achieve a physiological and / or olfactory response in the user. The active ingredient may be selected from, for example, dietary supplements, nootropics, and psychoactives. The active ingredient may be naturally occurring or synthetically obtained. The active ingredient may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, or components, derivatives, or combinations thereof. The active ingredient may include components, derivatives, or extracts of tobacco or another botanical material. In some embodiments, the active ingredient is a physiological active ingredient and may be selected from nicotine, nicotine salts (e.g., nicotine ditartrate / nicotine bitartrate), nicotine-free tobacco substitutes, other alkaloids such as caffeine, or mixtures thereof.

[0091] In some embodiments, the active ingredient is an olfactory active ingredient and may be selected from "fragrances" and / or "flavorings," which, where permitted by local regulations, are intended to provide a desired flavor, aroma, or other somatosensory sensation in products for adult consumers.In some instances, such components may be referred to as flavors, flavorings, cooling agents, heating agents, or sweetening agents. Such components may include naturally occurring flavoring substances, botanical substances, extracts of botanical substances, synthetically obtained substances, or combinations thereof (e.g., tobacco, cannabis, liquorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, etc.). , red berries, cranberries, peaches, apples, tangerines, mangoes, clementines, lemons, limes, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, mint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, Betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, burdock, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange skin, rose, green tea or red tea. teas such as tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, scutellaria, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damiane, oregano, olive, lemon balm, lemon basil, chive, caramel, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitter taste receptor site blockers, sensory receptor site activators or sensory receptor site stimulants.stimulators), sugar and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, saccharose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. Such components may be imitation, synthetic, or natural, or mixtures thereof. Such components may be, for example, liquids such as oils, solids such as powders, or extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, Dutch peppermint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, The components may be in any suitable form, such as one or more gases of ylang-ylang, sage, fennel, bell pepper, ginger, anise, coriander, coffee, or mint oil from any species of the genus Mentha), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulators, sugar and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, saccharose, glucose, fructose, sorbitol, or mannitol), and other additives, such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. Such components may be imitation, synthetic, or natural substances, or mixtures thereof. Such components may be in any suitable form, such as, for example, oils, liquids, or powders.

[0092] In some embodiments, the flavoring comprises menthol, oak, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or redberry flavoring ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavoring ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavoring ingredients extracted from cannabis. In some embodiments, the flavoring may comprise a sensate intended to achieve somatosensory perception, usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the smell or taste nerves, which may include agents that provide a heating effect, a cooling effect, a tingling effect, a numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0093] The carrier component can include one or more components capable of forming an aerosol. In some embodiments, the carrier component can include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0094] The one or more functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0095] In some embodiments, a consumable for use with an aerosol delivery device may comprise an aerosol generating substance or an area for receiving an aerosol generating substance. In some embodiments, a consumable for use with an aerosol delivery device may comprise a mouthpiece. The area for receiving an aerosol generating substance may be a storage area for storing the aerosol generating substance. For example, the storage area may be a reservoir. In some embodiments, the area for receiving an aerosol generating substance may be separate from or combined with the aerosol generation area.

[0096] Devices are known that heat an aerosol generating substance to volatilize at least one component of the aerosol generating substance to form an aerosol that can be inhaled, usually without burning or combusting the aerosol generating substance. Such devices are sometimes described as "aerosol generating devices", "aerosol delivery devices", "non-combustion heating devices", "tobacco heating product devices", or "tobacco heating devices", or the like. There are also so-called e-cigarette devices that vaporize an aerosol generating substance, which may or may not contain nicotine, and is generally in liquid form. The aerosol generating substance may be in the form of a rod, cartridge, cassette, or the like that can be inserted into the device, or may be provided as part of such a rod, cartridge, cassette, or the like. An aerosol generating device, such as a heating device, for heating and volatilizing the aerosol generating substance may be provided as a "permanent" part of the device.

[0097] Such devices may receive a consumable that includes the aerosol generating material for heating. A "consumable" in this context is an item that includes or is composed of an aerosol generating material that is intended to be consumed in part or in whole during use by a user. In some embodiments, the consumable is heated to volatilize the aerosol generating material and optional other components upon use. In other embodiments, heating may not be used to volatilize the aerosol generating material, for example vibration may be used to generate the aerosol. The consumable may be inserted into the aerosol generating device by a user before it is heated to create the aerosol, and the user then inhales the aerosol. The consumable may be of a predetermined or specific size, for example configured to be placed in a chamber, such as a heating chamber of the device, sized to receive the consumable.

[0098] 1, there is shown a schematic perspective view of an aerosol delivery system 10 comprising an aerosol delivery device 1 (see FIG. 2) according to an embodiment of the present invention, with a consumable 21 inserted into the device 1. The aerosol delivery device 1 is also referred to herein as an apparatus.

[0099] The device 1 is for heating an aerosol generating material to volatilize at least one component of the aerosol generating material to form an aerosol for inhalation by a user. In this embodiment, the aerosol generating material comprises tobacco and the device 1 is a tobacco heating product (also known in the art as a tobacco heating device or a non-combustion heating device). The device 1 is a handheld device for inhalation of the aerosol generating material by a user of the handheld device.

[0100] The device 1 comprises a first end 3 and a second end 5 opposite the first end 3. The first end 3 is sometimes referred to herein as the mouth end or proximal end of the device 1. The second end 5 is sometimes referred to herein as the distal end of the device 1. The device 1 has an on / off button 7 for allowing the device 1 as a whole to be turned on and off as desired by a user of the device 1. In some embodiments, activation mechanisms other than an on / off button may be used to turn the device on and / or off. Exemplary activation mechanisms include voice activation.

[0101] Generally, the device 1 is configured to generate an aerosol to be inhaled by a user by heating an aerosol generating substance. In use, a user inserts a consumable 21 into the device 1 and activates the device 1, for example using button 7, to cause the device 1 to begin heating the aerosol generating substance. The user then inhales with a mouthpiece 21b of the consumable 21 near a first end 3 of the device 1 to inhale the aerosol generated by the device 1. As the user inhales with the consumable 21, the generated aerosol flows through the device 1 along a flow path toward the proximal end 3 of the device 1.

[0102] In an embodiment, vapour is produced which then at least partially condenses to form an aerosol before exiting the device 1 for inhalation by the user.

[0103] In this regard, it should first be noted that a vapor is generally a substance that is in the gas phase at a temperature below its critical temperature, meaning that the vapor can be condensed into a liquid, for example by increasing the vapor's pressure without decreasing the temperature. An aerosol, on the other hand, is generally a colloid of tiny solid particles or liquid droplets in air or another gas. A "colloid" is a substance in which microscopically dispersed insoluble particles are suspended amongst another substance.

[0104] For convenience, the term aerosol as used herein should be taken to mean an aerosol, a vapor, or a combination of aerosol and vapor.

[0105] The device 1 comprises a casing 9 for locating and protecting various internal components of the device 1. The casing 9 is thus an outer housing for containing the internal components. In the embodiment shown, the casing 9 comprises a sleeve 11 that surrounds the periphery of the device 1 and is capped at a first end 3 by a top panel 17 that generally defines a "top" of the device 1, and at a second end 5 (see Figures 2-5) by a bottom panel 19 that generally defines a "bottom" of the device 1.

[0106] The sleeve 11 includes a second sleeve 11a and a first sleeve 11b. The second sleeve 11a is provided at a top portion of the device 1 and is shown as an upper portion of the device 1, extending in a direction away from the first end 3. The first sleeve 11b is provided at a bottom portion of the device 1 and is shown as a lower portion of the device 1, extending in a direction away from the second end 5. The second sleeve 11a and the first sleeve 11b each surround the periphery of the device 1. That is, the device 1 has a longitudinal axis in the Y-axis direction, and the second sleeve 11a and the first sleeve 11b each surround the internal components in a direction that is radial to the longitudinal axis.

[0107] The top panel 17 of the device 1 has an opening 20 at the mouth end 3 of the device 1 through which, in use, a consumable 21 containing an aerosol generating substance is inserted into and removed from the device 1 by a user. In this embodiment, the insertion and removal directions are each parallel to the longitudinal axis AA of the hollow internal heating chamber 29. In this embodiment, the longitudinal axis AA is in a direction parallel to the longitudinal axis of the device 1. In this embodiment, the consumable 21 functions as a mouthpiece for a user to place between the user's lips. In other embodiments, an external mouthpiece may be provided, in which at least one volatile component of the aerosol generating substance is inhaled through the mouthpiece. When an external mouthpiece is used, no aerosol generating substance is provided within the external mouthpiece.

[0108] The opening 20, in this embodiment, is opened and closed by a door 4. In the embodiment shown, the door 4 is movable between a closed position and an open position to allow for the insertion of a consumable 21 into the device 1 when in the open position. The door 4 is configured to move in both directions along the X-axis direction.

[0109] A connection port 6 is shown at the second end 5 of the device 1. The connection port 6 is for connecting a cable and a power source 27 (shown in FIG. 6) to charge the power source 27 of the device 1. The connection port 6 extends in the Z-axis direction from the front side of the device 1 to the rear side of the device 1. As shown in FIG. 1, the connection port 6 is accessible from the right side of the device 1 at the second end 5 of the device 1. It is advantageous that the device 1 can stand on its second end 5 during charging or to realize a data connection through the connection port 6. In the embodiment shown, the connection port 6 is a USB socket.

[0110] FIG. 2 shows a schematic cross-sectional front view of the device 1 shown in FIG. 1 with the consumable 21 of FIG. 1 withdrawn.

[0111] The casing 9 has the heating device assembly 23, the control circuit 25 and the power supply 27 mounted or fixed therein. In this embodiment, the control circuit 25 is part of the electronics compartment and comprises two printed circuit boards (PCBs) 25a, 25b. In this embodiment, the control circuit 25 and the power supply 27 are laterally adjacent to the heating device assembly 23 (i.e. adjacent when viewed from the end), and the control circuit 25 is located below the power supply 27. This advantageously allows the device 1 to be compact in the lateral direction corresponding to the X-axis direction.

[0112] The control circuit 25 in this embodiment has a controller 81, such as a microprocessor arrangement, constructed and arranged to control the heating of the aerosol generating material within the consumable 21, as will be further discussed below. The control circuit 25 further has a detection arrangement 83 for detecting the electrical resistance of at least one continuous conductive track, such as a conductive path, discussed below, in the form of a conductive track or conductive wire.

[0113] The power source 27, in this embodiment, is a rechargeable battery. In other embodiments, a non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to the main power source may be used. Examples of suitable batteries include, for example, lithium ion batteries, nickel batteries (such as nickel cadmium batteries), and / or alkaline batteries. The battery 27 is electrically coupled to the heater arrangement 23 to provide power under the control of the control circuitry 25 when needed to heat the aerosol generating material within the consumable (for the purpose of volatilizing the aerosol generating material without burning it, as will be discussed).

[0114] An advantage of locating the power source 27 laterally adjacent to the heating device arrangement 23 is that a physically larger power source 27 may be used without unduly lengthening the device 1 as a whole. As will be appreciated, a physically larger power source 27 generally has a greater capacity (i.e., total electrical energy that can be delivered, often measured in ampere-hours or the like) and therefore may extend the battery life for the device 1.

[0115] In one embodiment, the heater configuration 23 is generally in the form of a hollow cylindrical tube with a hollow internal heating chamber 29 into which the consumable 21 having the aerosol generating substance is inserted for heating during use. Generally speaking, the heating chamber 29 is a heating zone for receiving the consumable 21. Alternative configurations for the heater configuration 23 are possible. In some embodiments, the heater configuration 23 can comprise a single heating element or can be formed of multiple heating elements aligned along the longitudinal axis of the heater configuration 23. The or each heating element may be annular or tubular or at least partially annular or tubular around its circumference. In an embodiment, the or each heating element may be a thin film heater. In another embodiment, the or each heating element may be made of a ceramic material. Examples of suitable ceramic materials include alumina and aluminum nitride and silicon nitride ceramics, which can be layered and sintered. Other heating device configurations are also possible, including, for example, induction heating, infrared heater elements which heat by emitting infrared radiation, or resistive heating elements formed, for example, by electrical resistance windings.

[0116] In this embodiment, the heater assembly 23 is supported by a stainless steel support tube 75 and comprises a heater 71. In one embodiment, the heater 71 comprises a substrate and at least one conductive element is formed within the substrate. The substrate may be in the form of a sheet and may comprise, for example, a plastic layer. In a preferred embodiment, the layer is a polyimide layer. The conductive element may be printed or otherwise deposited within the substrate layer. The conductive element may be encapsulated within the substrate or coated by the substrate.

[0117] The support tube 75 is the heating element that transfers heat to the consumable 21. Thus, the support tube 75 comprises a heating material. In this embodiment, the heating device material is stainless steel. In other embodiments, other metallic materials may be used as the heating material. For example, the heating material may comprise a metal or a metal alloy. The heating material may comprise one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, ferritic stainless steel, molybdenum, copper, and bronze.

[0118] The heater arrangement 23 is dimensioned such that, in use, when the consumable 21 is inserted into the device 1, substantially the entire aerosol generating material is heated.

[0119] In some embodiments, the, or each, heating element may be configured to allow for independent heating of selected zones of the aerosol generating material, e.g., in sequence (over time) or in unison (simultaneously), as desired.

[0120] The heater component 23 is surrounded by a vacuum region 31 along at least a portion of its length in this embodiment. The vacuum region 31 helps to reduce heat passing from the heater component 23 to the exterior of the device 1. This generally reduces heat loss, thereby helping to keep the power requirements of the heater component 23 low. The vacuum region 31 also helps to maintain a low temperature outside the device 1 during operation of the heater component 23. In some embodiments, it may be surrounded by a double-walled sleeve, where the area between the two walls of the sleeve is evacuated to provide a low pressure region to minimize heat transfer by conduction and / or convection. In other embodiments, a different insulating component may be used in addition to or instead of the vacuum region, for example using insulating materials, including for example suitable foam-type materials.

[0121] The casing 9, sometimes referred to as the housing, may further comprise various internal support structures 37 (best seen in FIG. 6) for supporting all the internal components as well as the heating device assembly 23.

[0122] The device 1 further comprises a collar 33 that extends around and projects from the opening 20 into the interior of the housing 9, and an expansion element 35 located between the collar 33 and one end of the vacuum region 31. The expansion element 35 is funnel shaped to form an expansion chamber 40 at the mouth end 3 of the device 1. The collar 33 is a retainer for holding the consumable 21. In this embodiment, the retainer is reversibly removable from the device 1.

[0123] One end of the enlargement element 35 is connected to and supported by the second sleeve 11a, and the other end of the enlargement element 35 is connected to and supported by one end of the cassette 51. A first sealing element 55, shown as an o-ring, is interposed between the enlargement element 35 and the second sleeve 11a, and a second sealing element 57, also shown as an o-ring, is interposed between the enlargement element 35 and the cassette 51. Each o-ring is made of silicone, although other elastic materials may be used to provide a seal. The first sealing element 55 and the second sealing element 57 prevent the permeation of gas into the surrounding components of the device 1. A sealing element is also provided at the distal end, thereby preventing the ingress and egress of fluids at the distal end.

[0124] As can best be seen in FIG. 2, the collar 33, the expansion element 35, and the vacuum region 31 / heating device assembly 23 are arranged coaxially so that when the consumable 21 is inserted into the device 1, the consumable 21 extends through the collar 33 and the expansion element 35 into the heating chamber 29.

[0125] As mentioned above, in this embodiment, the heating device component 23 is generally in the form of a hollow cylindrical tube that defines a heating chamber 29 that is in fluid communication with the opening 20 at the mouth end 3 of the device 1 via an enlarged chamber 40.

[0126] In this embodiment, the expansion element 35 comprises a tubular body having a first open end adjacent the opening 20 and a second open end adjacent the heating chamber 29. The tubular body comprises a first section extending from the first open end approximately halfway along the tubular body and a second section extending from approximately halfway along the tubular body to the second open end. The first section comprises a flared portion expanding away from the second section. Thus, the first section has an inner diameter that tapers outwardly toward the first open end of the opening. The second section has a substantially constant inner diameter.

[0127] As best seen in FIG. 2, in this embodiment, the expansion element 35 is located within the housing 9 between the collar 33 and the vacuum area 31 / heating device assembly 23. More specifically, at the second open end, the expansion element 35 is interposed between an end portion of the support tube 75 of the heating device assembly 23 and the interior of the vacuum area 31, such that the second open end of the expansion element 35 is engaged with the support tube 75 and the interior of the vacuum area 31. At the first open end, the expansion element 35 receives the collar 33, such that the legs 59 of the collar 33 protrude into the expansion chamber 40 to loosely press or clamp the consumable 21. Thus, when the consumable 21 is received within the device 1 and when the consumable 21 is not present, the inner diameter of the first section of the expansion element 35 is larger than the outer diameter of the legs.

[0128] A top panel 17 generally forms a first end 3 of a housing 9 of the device 1. The top panel 17 supports a collar 33 that defines an insertion point in the form of an opening 20 through which a consumable 21 is removably inserted into the device 1 during use.

[0129] In this embodiment, the consumable 21 is in the form of a cylindrical rod having or containing the aerosol generating material at its rear end within a section of the consumable 21 that is within the heating device arrangement 23 when the consumable 21 is inserted into the device 1. The front end of the consumable 21 extends from the device 1 and functions as a mouthpiece, which is an assembly having one or more of a filter for filtering the aerosol and / or a cooling element for cooling the aerosol. The filter / cooling element is spaced from the aerosol generating material by a space. The consumable 21 is circumferentially surrounded in an outer layer (not shown). In this embodiment, the outer layer of the consumable 21 is permeable to allow some heated volatile components from the aerosol generating material to escape the consumable 21.

[0130] During operation, the heater arrangement 23 will heat the consumable 21 to volatilize at least one component of the aerosol generating material.

[0131] As shown in FIG. 2, the support tube 75 is surrounded by the heating device 71 on the outside. In this example, the heating device 71 is a thin film heating device including polyimide and conductive elements. The heating device 71 can include multiple heating zones that are independently controlled and / or simultaneously controlled. In this example, the heating device 71 is formed as a single heating device. However, in other embodiments, the heating device 71 can be formed of multiple heating devices aligned along the longitudinal axis of the heating chamber 29. In some embodiments, multiple temperature sensors can be used to detect the temperature of the heating device 71 and / or the support tube. The support tube 75 is made of stainless steel, which in this embodiment conducts heat from the heating device 71 to the consumable 21 when the consumable 21 is inserted into the heating zone (the heating zone is defined by the heat conducting area of ​​the support tube 75). In other embodiments, the support tube 75 can be made of a different material, so long as the support tube 75 is thermally conductive. In other embodiments, other heating elements 75 can be used. For example, the heating element can be a susceptor that can be heated by induction. In this embodiment, the support tube 75 serves as an elongated support for supporting the consumable 21 containing the aerosol generating material during use.

[0132] In this embodiment, the heater 71 is located outside the support tube 75. However, in other embodiments, the heater 71 can be located inside the support tube 75. The heater 71, in this embodiment, has a portion that passes outside the support tube 75, referred to herein as the heater tail 73. The heater tail 73 extends beyond the heating chamber 29 and is configured to be electrically connected to the control circuit 25. In the embodiment shown, the heater tail 73 is physically connected to one PCB 25a. The power source 27 provides current to the heater 71 via the control circuit 25 and the heater tail 73.

[0133] 3 and 4, there are shown first and second schematic views, respectively, of an assembly 100 for the aerosol delivery device 1 of FIG. 1 according to an embodiment of the present invention. The first view of FIG. 3 corresponds to the Z axis. The second view of FIG. 4 corresponds to the X axis.

[0134] Assembly 100 includes heating zone 29 as discussed above, and consumable 21 including an aerosol generating material is inserted into heating zone 29 to be heated. In this embodiment, consumable 21 is inserted into heating zone 29 in a direction parallel to longitudinal axis AA of heating zone 29. In this embodiment, assembly 100 includes a heating element shown as support tube 75 as discussed above. In other embodiments, assembly 100 does not include support tube 75.

[0135] The assembly 100 comprises an electrical structure 101' comprising two conductive tracks 103, 203 formed on an electrically insulating track 105. The tracks 103, 203 are an example of a conductive path. The electrically insulating substrate 105 is a structure configured to provide support for the tracks 103, 203. In other embodiments, conductive wires can be used instead of the conductive tracks.

[0136] In this embodiment, the substrate 105 is in the form of a sheet and comprises a plastic layer. The substrate 105 is rolled to form a tube. In this embodiment, the substrate is rolled around the support tube 75. As shown in Figures 3 and 4, when the substrate 105 is rolled around the support tube 75, the heater tail 73 is rolled to a certain extent. The first track 103 is formed on the conductive substrate 105. In this embodiment, the track is formed by evaporating onto the substrate. In other embodiments, the track is formed by printing onto the substrate. In some embodiments, the first track 103 is electrodeposited onto the substrate 105. In other embodiments, the first track 103 is layered onto the substrate 105. Electrodepositing the first track 103 is advantageous because of cost savings. Layering the first track 103 represents a more reliable solution than electrodepositing the first track 103 onto the substrate 105. When wrapped around the support tube 75, the first track 103 conforms to the shape of the support tube 75 with minimal deviation from the outer surface of the support tube 75. This aids in efficient heat transfer, and in some instances, this additionally helps reduce the risk of the first track 103 being damaged.

[0137] In other embodiments, the tracks are formed by an etching process. In some embodiments, the etching process corresponds to a process utilized in the manufacture of printed circuit boards (PCBs). In some embodiments, the etching process includes removing material formed on a base layer by etching material from the base layer. The material that is not etched, i.e., the material that remains, is used to form the base of the conductive tracks. In some embodiments, an etch resist is coupled to a portion of the material, such that the material that is not etched remains, and this portion forms the base of the conductive tracks. In some embodiments, the non-etched pattern may be formed by a photolithographic process.

[0138] In other embodiments, the conductive path may be a conductive wire 103a encapsulated by an electrically insulating element 103' as shown in Figure 4A. In such embodiments, the wire 103a is not formed by an etching process as described above. The wire 103a is enveloped by a sheath of electrically insulating material that corresponds to the electrically insulating element 103' as shown in Figure 4A and discussed below.

[0139] In this embodiment, the first track 103 and the second track 203 detect the temperature of the heating zone 29 based on the electrical resistance of the respective first track 103 and second track 203. In other embodiments, the first track 103 and the second track 203 function as a heating device for heating the heating zone 29 by resistive heating. In another embodiment, the first track 103 and the second track 203 detect the temperature of the heating zone 29 as a first function and heat the heating zone 29 as a second function. In the latter embodiment, the functions of the first track 103 and the second track 203 are interchangeable. In some embodiments, the first track 103 and the second track 203 perform one of the first and second functions. In other embodiments, the first track 103 is configured to perform one of the first and second functions different from the second track 203. When performing the function of detecting the temperature, the track creates negligible heat that is insufficient to generate an inhalable medium. That is, the first function is not capable of generating an aerosol from the aerosol generating material.

[0140] The first track 103 is shown extending along three separate portions 107, 109, 111 of the substrate 105. In other embodiments, the first track 103 extends along at least two separate portions 107, 109 of the substrate 105. The second track 105 is constructed and arranged on the substrate 105 in a similar manner but spaced apart from the first track 103, and is adjacent to the first track 103 and does not overlap the first track 103. The separate portions 107, 109, 111 of the substrate 105 provide efficient coverage of the substrate 105 both in the direction of the longitudinal axis AA and in the circumferential direction of the heating zone 29. The use of the separate portions 107, 109, 111 of the substrate 105 allows stress relief, in particular thermal stress relief.

[0141] The portions 107, 109, 111 of the first track 103 are distinct from each other because they are offset from each other by the gap 115. The gap 115 allows the first track 103 to move during the expansion and contraction of the first track 103. This movement helps to relieve mechanical stresses applied to the first track 103 under operational thermal conditions. For example, the operational conditions include temperatures experienced by the first track 103 when performing a first function of detecting temperature or a second function of heating the heating zone 29. Thus, the gap 105 helps to reduce stresses in the first track 103 to avoid mechanical damage that may affect the performance of the first track 103. This provides improved reliability by reducing the risk of cracks in the track. The gap 115 is shown without the first track 103 in this figure. In other embodiments, the gap 115 is substantially free of the first track 103 , where only a portion of the first track 103 that interconnects the separate portions 107 , 109 , 111 of the substrate 105 is present within the gap 115 .

[0142] The first track 103 and the second track 203 each comprise a number of turns 113. The number of turns 113 of the first track 103 are shown in each of the three separate parts 107, 109, 111 of the substrate. In other embodiments, the assembly 100 can comprise multiple separate parts. The second track 203 is arranged in a similar manner. In the illustrations shown in Figures 3 and 4, the number of turns 113 comprises a turn with a rotation angle of 180 degrees. The number of turns 113 interconnects a number of straight sections, as shown more clearly in Figure 6. One straight section of each of the number of straight sections is parallel to one another and extends in the direction of the longitudinal axis AA. In some embodiments, the main sections of the number of straight sections may be parallel to one another. In some embodiments, the main sections of the number of straight sections can extend in the direction of the longitudinal axis AA. If the number of straight sections extends in the direction of the longitudinal axis AA, and in particular if the heating zone 29 has a circular cross section, the mechanical stress applied to the track is reduced. The use of multiple turns minimizes alignment of the track in a non-linear direction, such as the circumferential direction. Minimizing the length of track that exists in a non-linear direction helps reduce the mechanical stresses placed on the track, allowing the track to perform reliably at an optimum level.

[0143] In this embodiment, the heating zone 29 comprises a first heating zone 29a and a second heating zone 29b, each corresponding to a first track 103 and a second track 203, respectively. In this embodiment, the first track 103 is for detecting the temperature of the first heating zone 29a, and the second track 203 is for detecting the temperature of the first heating zone 29b. In other embodiments, the first track 103 is for heating the first heating zone 29a, and the second track 203 is for heating the first heating zone 29b.

[0144] In this embodiment, the first track 103 and the second track 203 include multiple straight portions 127. Any one of the multiple straight portions 127 extends only partially around the heating zone 29. The multiple straight portions 127 assist in reducing stresses applied to the tracks 103, 203 due to the widening of the tracks 103, 203 in use.

[0145] As best shown in FIG. 4, the substrate 105 includes a heater tail 73 that passes outside the support tube 75, as described above. The heater tail 73 includes electrical contacts 77 for connection to the control circuit 25 shown in FIG. 2. The electrical contacts 77 include a first electrical connection between the first track 103 and the control circuit 25, and a second electrical connection between the second track 203 and the control circuit 25. If a second substrate layer is used, such as the second substrate 1101 shown in FIG. 15 and discussed below, the electrical contacts 77 include a third electrical connection between the first outer track 1103 and the control circuit 25, and a fourth electrical connection between the second outer track 1203 and the control circuit 25. The heater tail 73 includes a connection portion 74 extending from the heating zone 29, which is a narrowed portion compared to the area of ​​the heater tail 73 that includes the electrical contacts 77. Heater tail 73 is shown in a flat configuration in Figures 3 and 4 and is bent when installed in device 1 shown in Figures 1 and 2. Thus, assembly 100 has a length 12 that is reduced when installed in device 1.

[0146] With reference to Fig. 4A, a schematic cross-sectional view of an alternative assembly 100' is shown. The assembly 100' of Fig. 4A differs from the assembly 100 of Figs. 3 and 4 in that a wire 103a is used instead of the first track 103. The wire 103a is an example of a conductive path. The features described herein in relation to the track configuration also apply to the embodiment in which the path is a wire 103a, except for the etching process. That is to say, the features of the tracks 103, 203, 1103, 1203 of the electrical structures 101, 1101 shown in Figs. 5 and 17, respectively, also apply to the case in which the path is a wire 103a.

[0147] Instead of being formed on an electrically insulating base 105, the wire 103a is encapsulated by an electrically insulating element 103'. The wire 130a encapsulated by the electrically insulating element 103' is attached to the structure 105' by a fastening member 103''. In this embodiment, the fastening member 103'' is an adhesive. In other embodiments, the fastening member 103'' may be a mechanical coupling. In some embodiments, the structure 105' may be a conductive element. For example, in some embodiments, the structure 105' may correspond to the support tube 75. In this embodiment, the wire 103a has a circular cross-section along substantially the entire length of the wire 103a.

[0148] Referring to Figure 5, there is shown a schematic diagram of electrical component 101 which is a particular embodiment of electrical component 101' shown in assembly 100 shown in Figures 3 and 4. Features already described in relation to Figures 3 and 4 are given the same reference numerals in Figure 5 as given in Figures 3 and 4.

[0149] The electrical structure 101 is shown in a flat configuration in FIG. 5. The electrical structure 101 is adapted to be wrapped around the support tube 75 to provide the tube configuration shown in FIG. 3 and FIG. 4. In some embodiments, the heater tail 73 is wrapped to a certain extent when the substrate 105 having the tracks 103, 106 formed thereon is wrapped around the support tube 75. In other embodiments, only the connection portion 74 of the heater tail 73 is wrapped to a certain extent when the substrate 105 having the tracks 103, 106 thereon is wrapped around the support tube 75. In other embodiments, the heater tail 73 is configured to be wrapped around the support tube 75. In some embodiments, the heater tail 73 is provided at about 90 degrees relative to the orientation shown in FIG. 4. That is, the heater tail 73 is provided at about 90 degrees relative to the X-axis or Z-axis.

[0150] Both the first track 103 and the second track 203 are provided on the same side 110 of the substrate 105. In this embodiment, the first track 103 and the second track 203 are deposited on the same surface of the substrate 105. This surface is shown in a flat configuration when the electrical component 101 is provided as part of the assembly 100 as shown in Figures 3 and 4, but because the substrate 105 is wrapped around the support tube 75, this surface is arcuate. In the embodiment of Figures 3 and 4, the heating zone 29 has a circular cross section, and therefore this surface is circular. The flat configuration allows the first track 103 and the second track 203 to be best shown for discussion.

[0151] As shown in FIG. 5, the first track 103 is arranged on the substrate 105 in a first region 106, and the second track 203 is arranged on the substrate 105 in a second region 206. The first region 106 and the second region 206 are shown by dashed circles for illustrative purposes. The portions of the tracks 103, 203 that are in the first region 106 and the second region 206 are shown by thick lines for illustrative purposes. The first region 106 and the second region 206 are offset from each other by a gap 169. The gap 169 between the first region 106 and the second region 206 is larger than the gap 115 between the separate portions 107, 109 of the first track 103 shown in FIG. 3 and FIG. 4. The larger gap 169 allows for a clear separation of the temperature detection zone and the heating zone. Thus, the larger gap 169 establishes two different zones and reduces the influence of one zone on the other zone. In this embodiment, the larger gap 169 is absent the first track 103 and the second track 150. This helps reduce or avoid interference between the first region 106 and the second region 206.

[0152] The second track 203 is shown as substantially a mirror image of the first track 103, centered about an imaginary line BB between the first track 103 and the second track 203. For example, at least one of the distinct portions of the first track 103 and the second track 203 comprises substantially equal sub-portions, and the other two distinct portions comprise substantially equal sub-portions. In other embodiments, the second track 203 may not be a mirror image of the first track 103, provided that the centers of each of the first region 106 and the second region 206 are accurately located.

[0153] As shown in Fig. 5, the main straight portions of the first track 103 and the second track 203 extend in a first direction D1, which is intended to be aligned with the longitudinal axis AA of the assembly 100. This allows the main straight portions to be aligned with the longitudinal direction Y of the heating zone 29, which is intended to be parallel to the longitudinal axis AA of the assembly 100 when the assembly 100 is installed in the device 1. A second direction D2 is shown perpendicular to the first direction D1. In this embodiment, the non-main straight portions extend in the second direction D2.

[0154] Each of the first and second tracks 103, 203 in the respective first and second regions 106, 206 comprises a first portion 104, 204 corresponding to a first turn or a first straight portion of the first and second regions 106, 206. Similarly, each of the first and second tracks 103, 203 in the respective first and second regions 106, 206 comprises a second portion 108, 208 corresponding to a last turn or a last straight portion of the first and second regions 106, 206.

[0155] Referring to Figure 6, there is shown a schematic enlarged view of one of the conductive tracks 103, 105 shown in Figure 5, according to an embodiment of the present invention. One of the tracks 103, 105 is, for illustrative purposes, the first track 103.

[0156] The configuration of multiple turns 113 and straight portions 127 of the track 103 varies in the number of turns 113 and straight portions 127 and the length of each straight portion 127 in each distinct portion 107, 109.

[0157] A first separate portion 107 of the separate portions, referred to herein as first separate portion 107, is shown in short dashed lines. A second separate portion 109 of the separate portions, referred to herein as second separate portion 109, is shown in long dashed lines. A third separate portion 111 of the separate portions, referred to herein as third separate portion 111, is shown in dashed and dotted lines.

[0158] Each of the short dashed, long dashed, and dot-dash lines represents a boundary 107', 109', 111' of each respective separate portion 107, 109, 111. In this embodiment, each boundary 107', 109', 111' is rectangular in shape. In other embodiments, other configurations are possible. Thus, each boundary 107', 109', 111' is formed of four boundary lines, each parallel to another boundary line.

[0159] The first separate portion 107 includes first to fourth boundary lines 107a-d. The second separate portion 109 includes first to fourth boundary lines 109a-d. The third separate portion 111 includes first to fourth boundary lines 111a-d.

[0160] The first boundary line 107a, 109a, 111a and the third boundary line 107c, 109c, 111c of each separate portion 107, 109, 111 are parallel to each other and perpendicular to the second boundary line 107b, 109b, 111b and the fourth boundary line 107d, 109d, 111d.

[0161] Boundary lines define the extent of each separate portion. In some embodiments, the boundary lines 107a-d, 109a-d, 111a-d abut the edges of the track. In some embodiments, each boundary 107', 109', 111' defines a rectangle (e.g., a square or rectangle) of the smallest possible size to enclose the separate portion of the track and define the gaps 115, 117. Applying this to the embodiment of FIG. 6 means that the first boundary lines 107a, 109a and the third boundary lines 107c, 109c of the first and second separate portions 107, 109 will abut and will extend along straight portions 127 located at the ends of the respective first and second separate portions 107, 109. Similarly, this means that the second boundary lines 107b, 109b, 111b and the fourth boundary lines 107d, 109d, 111d of the first to third separate portions 107, 109, 111 will be abutted and will extend tangent to the main portions of the turns of the multiple turns 127 arranged at the edges of the respective first to third separate portions 107, 109, 111.

[0162] In this embodiment, one separate portion 109 is adjacent to two other separate portions 107, 111. Furthermore, the first separate portion 107 and the second separate portion 111 are each adjacent to the second separate portion 109. The first separate portion 107 is separated from the second separate portion 109 by a first gap 115, and the second separate portion 109 is separated from the third separate portion 111 by a second gap 117. The first gap 115 and the second gap 117 have equal widths. In other embodiments, the gaps 115, 117 can have different widths, but are greater than the spacing between the straight portions 127.

[0163] In the embodiment shown, the size of the second border 109' is the smallest of the three borders 107', 109', 111'. The second border 109' is shown as having the largest width, while the first border 107' is shown as having the smallest width. The first border 107' and the second border 109' have equal lengths, and both are greater than the length of the third border 111'.

[0164] The length and width directions of each of the separate portions 107, 109, 111 are parallel to each other of the separate portions 107, 109, 111. That is, there is no rotation angle between the separate portions 107, 109, 111.

[0165] The configuration of the multiple turns 113 and straight portions 127 of the first track 103 varies in each distinct portion 107, 109, 111. The first track 103 follows a convoluted pathway. The convoluted pathway comprises 90 degree turns and 180 degree turns primarily spaced apart by straight portions. In some embodiments, the convoluted pathway comprises turns including any turns greater than 0 degrees and less than 180 degrees. The convoluted pathway essentially forms two types of repeating patterns in each distinct portion 107, 109, 111.

[0166] The first repeating pattern has a straight portion 127 that extends across the entire width of the portions 107, 109, 111 from one boundary line 107b, 109b, 109b to another boundary line 107d, 109d, 111d. The first repeating pattern has substantially all 180 degree turns of the first track 103 in the first portion 107 and the third portion 111 and extends along more than 70% of the width of the individual portions 107, 111. The first repeating pattern extends along less than 70% of the width of the second distinct portion 109.

[0167] The second repeating pattern has a straight portion 127 that extends only partially along the width of the second distinct portion 109 from one border line 107b, 109b to another border line 107d, 109d. The second repeating pattern is shown only within the second distinct portion 109 and is closer to the first border line 109a than to the third border line 109c.

[0168] The convoluted pathway of the first track 103 extends from the first portion 104 to the second portion 108. The first portion 104 comprises a straight portion 127 and the second portion 108 comprises a turn 113. The first portion 104 is at a first end 107a' of the first separate portion 107. The first track 103 alternates from end to end in a direction D1 and from left to right in a direction D2 within the first separate portion 107. The first track 103 alternates from the first portion 104 to a first side 107b', and from the first side 107b' to a second side 107d' toward a second end 107c' opposite the first end 107a'. The first track 103 then runs end-to-end in direction D1 within the third separate portion 111, from the first end 111a' to the second end 111c', between the first side 111b' and the second side 111d', alternating from side to side in direction D2 to the second separate portion 108. The first track 103 then runs end-to-end in direction D1 within the second separate portion 109, alternating from side to side in direction D2. However, the winding starts at the second side 109d' and ends at the first side 109b', and extends between the second end 109c' and the first end 109a'.

[0169] Because the first track 103 extends to or traverses different sides of the separate portions 107, 109, 111 of the base 105, each of the first ends 107a', 109a', 111a' and second ends 107c', 109c', 111c' may be referred to as a side.

[0170] FIG. 6 shows two connection portions 151, 153 of the first track 103 interconnecting the first to third separate portions 107, 109, 111. FIG. 6 also shows stress relief structures 139, 140 of the first track 103, shown as localised loop-backs, for reducing mechanical stresses when the first track 103 expands and contracts under thermal energy. When the first track 103 is viewed from above in a flat configuration, each connection portion 151, 153 and stress relief structure 139, 140 appears as a protrusion 140, 153 or a recess 139, 141, 151. The protrusions 140, 153 are portions of the first track 103 that protrude away from the centre of the gap 117. That is, the protrusions 140, 153 are outward turns that point away from the centre of the gap 117. The recesses 139, 141, 151 are parts of the first track 103 that protrude towards the centre of the gap 117. That is, the recesses 139, 141, 151 are inward turns towards the centre of the gap 117. An example of a recess is shown by a first area 159 of the first track 103. An example of a protrusion is shown by a second area 161 of the first track 103. The first area 159 and the second area 161 are further discussed below. The protrusions 140, 153 or the recesses 139, 141, 151 are considered as locations that are locally offset from the main pathway on either side of the protrusions 140, 153 or the recesses 139, 141, 151, respectively.

[0171] Referring to Figure 7, there is shown a schematic close-up view of a third area 160 of the first track 103 according to an embodiment of the present invention. The third area 160 is an area between the first separate portion 107 and the second separate portion 109 that are not directly connected. In Figure 6, the third area 160 is shown in relation to other parts of the first track 103.

[0172] The third area 160 shows a part of the gap 115 between a part of the track 103 in the first separate portion 107 and a part of the track 103 in the second separate portion 109. The gap 115 is shown with a size 131 represented by a width. In some embodiments, the size of the gap 115 can refer to the length of the gap 115. The width 131 of the gap 115 is substantially equal to the width 133 of each straight portion 127. In other embodiments, the size 113 (e.g., width) of the gap 115 can be greater than the width 133 of each straight portion 127 and can be less than twice the width 133 of each straight portion 127. In some embodiments, each straight portion 127 can include only the straight portion 127 adjacent to the gap 115, and the other straight portions 127 can be wider than the gap 115.

[0173] In this embodiment, the width 133 of each straight portion 127 is about 0.3 mm.

[0174] 7, the first boundary 107' and the second boundary 109' extend to the edges 123, 125 of the turn 113, such that the boundary line is tangent to the turn 113. This means that the gap 115 extends to the turn 113 in each of the first and second distinct portions 107, 109 of the substrate 105.

[0175] A size 130 of the space 129 between adjacent straight portions 127a, 127b of the track 103 is smaller than a size 131 of the space 115, such as a gap width 131. In this embodiment, the size of the space 129 is the space 129 width 130. In this embodiment, the space 129 width 130 is smaller than a width 133 of each straight portion 127. In this embodiment, the space 129 width 130 is about 0.2 mm.

[0176] Adjacent edges 119, 121 of the first track 103 are closer to one another within each of the first and second distinct portions 107, 109 of the substrate 105 as compared to adjacent edges 123, 125 of the first track 103 between the first and second distinct portions 107, 109 of the substrate 105. In this embodiment, the relatively closer adjacent edges 119, 121 are adjacent edges of straight portions 127 and the relatively farther apart adjacent edges 123, 125 are adjacent edges of straight portion turns 113.

[0177] Referring to FIG. 8, there is shown a schematic close-up view of the second area 161 of the first track 103 according to an embodiment of the present invention. The second area 161 is the area between the directly connected second separate portion 109 and the third separate portion 111. In this embodiment, the second area 161 shows the connection portion 153 as a protrusion. The connection portion 153 spans the second gap 117. In this embodiment, the connection portion 153 also serves as the stress relief structure 140 and may be referred to as either the connection portion 153 or the stress relief structure 140. In FIG. 6, the second area 161 is shown in relation to other parts of the first track 103.

[0178] The stress relief structure 140 comprises a first turn 141 in a first direction 142, followed by a second turn 143 in a second direction 144 and a third turn 148 in the first direction 142. In this embodiment, the first direction 142 is a counterclockwise direction and the second direction 144 is a clockwise direction. The first turn 141 and the third turn 148 are 90 degree turns because the first track 103 goes out of one straight section 127, has a 90 degree rotation angle through the first turn 141 and the third turn 148, and then enters another straight section 127. The second turn 143 is a 180 degree turn because the first track 103 goes out of one straight section 127, has a 180 degree rotation angle through the second turn 143, and then enters another straight section 127. The turns within the stress relief structure 140 allow the stress relief structure 140 to be space efficient. Additionally, each turn can expand in an arcuate manner rather than linearly, which improves contraction and expansion.

[0179] The length 145 of the first track 103 between the first turn 141 and the second turn 143 is smaller than the lengths 146, 147 of both the first turn 141 and the second turn 143. In this embodiment, the length 145 is the length of the straight portion 127. The length 150 of the first track 103 between the second turn 143 and the third turn 148 is smaller than the lengths 147, 149 of both the second turn 143 and the third turn 148. In this embodiment, the length 150 is the length of the straight portion 127. In some embodiments, the lengths 145, 150 of the straight portion 127 away from the second turn 143 may be zero, or at least negligible compared to the length 147 of the second turn 143.

[0180] 9, a schematic close-up view of the first area 159 of the first track 103 according to an embodiment of the present invention is shown. The first area 159 is the area between the directly connected first separate portion 107 and second separate portion 109. In this embodiment, the first area 159 shows the connection portion 151 as a recess. The connection portion 153 spans the first gap 115. In this embodiment, the connection portion 151 doubles as the stress relief structure 139 and may be referred to as either the connection portion 151 or the stress relief structure 139. In FIG. 6, the first area 159 is shown in relation to other parts of the first track 103.

[0181] Much like the stress relief structure 140 shown in Figure 8, the stress relief structure 139 shown in Figure 9 comprises a first turn 141 in a first direction 142, followed by a second turn 143 in a second direction 144 and a third turn 148 in the first direction 142. The difference between the stress relief structure 140 shown in Figure 8 and the stress relief structure 139 shown in Figure 9 is that the stress relief structure 139 shown in Figure 9 does not comprise a straight section on either side of the second turn 143. That is, the stress relief structure 139 shown in Figure 9 is made up of three turns joined together. This allows the stress relief structure 139 to be compact.

[0182] Referring to FIG. 10, a schematic close-up view of the first separate portion 107 of the first track 103 is shown. The first separate portion 107 has a length L1 between a first end 107a' and a second end 107c'. As shown in FIG. 14, the length L1 of the first separate portion 107 is equal to the length L2 of the second separate portion 109. Both the length L1 of the first separate portion 107 and the length L2 of the second separate portion 109 are measured between the outermost edges of the outermost straight portions 127. The first separate portion 107 is shown as comprising an array of rows in a single column. A row is defined by a number of straight portions 127. The width of a single column is shown as the distance between adjacent turns 113.

[0183] Referring to FIG. 11, a schematic enlarged view of the fourth area 114 of the first track 103 shown in FIG. 10 with a 180-degree turn 113a is shown. The 180-degree turn 113a is arc-shaped. The 180-degree turn 113a is a semicircular turn because the turn has a substantially semicircular shape. The 180-degree turn 113a can be understood as a perfect U-shaped curve. The width 135 of the track 103 within the 180-degree turn 113a is greater than the width 137 of the track 103 outside the 180-degree turn 113a. That is, the width 137 of the straight section 127 is smaller than the width of the 180-degree turn 113a. The width 135 of the 180-degree turn 113a is measured at the midpoint of the 180-degree turn 113a, which corresponds to the location of the 90 degrees through the 180-degree turn 113a. The width 135 at the midpoint of the 180-degree turn 113a corresponds to the maximum width. In this embodiment, the width 135 of the 180 degree turn 113a is about 0.5 mm. In this embodiment, the width 137 of the straight portion 127 is about 0.3 mm. The first track 103 widens towards and away from the midpoint of the 180 degree turn. In general, the 180 degree turn 113a is wider than the straight portion 127 to reduce the mechanical stress applied to the first track 103 within the 180 degree turn 113a. By providing a greater thickness to the turn compared to the straight portion, the adhesion of the turn to the substrate is improved because the contact area is increased.

[0184] 12, there is shown a schematic close-up view of the third separate portion 111 of the first track 103. The third separate portion 111 has a length L3 between a first end 111a' and a second end 111c'. The length L3 of the third separate portion 111 is less than the length L1 of the first separate portion 107 and the length L2 of the second separate portion 109. The length L3 of the third separate portion 111 is measured between the outermost edge of the turn 113 proximal to the first end 111a' and the outermost edge of the outermost straight portion 127 proximal to the second end 111c'.

[0185] Referring to FIG. 13, a schematic enlarged view of the fifth area 116 of the first track 103 shown in FIG. 10, which includes a 90-degree turn 113b, is shown. The 90-degree turn 113b is arc-shaped. The 90-degree turn 113b is a quarter-circle turn, since the turn has substantially a quarter circle. The 90-degree turn 113b can be understood as a half U-shaped curve. The width 173 of the track 103 within the 90-degree turn 113b is greater than the width 171 of the track 103 outside the 90-degree turn 113b. That is, the width 171 of the straight section 127 is smaller than the width of the 90-degree turn 113b. The width 173 of the 90-degree turn 113b is measured at the midpoint of the 90-degree turn 113b, which corresponds to the 45-degree location through the turn 113b. The width 173 at the midpoint of the turn 113b corresponds to the maximum width. In this embodiment, the width 173 of the 90 degree turn 113b is about 0.45 mm. In this embodiment, the width 171 of the straight portion 127 is about 0.3 mm. The first track 103 widens toward and away from the midpoint of the 90 degree turn 113b. In general, the 90 degree turn 113b is wider than the straight portion 127 to reduce the mechanical stresses applied to the first track 103 within the 90 degree turn 113b.

[0186] Referring to FIG. 14, a schematic enlarged view of the second separate portion 109 of the first track 103 is shown. The second separate portion 109 comprises a first sub-portion 163 and a second sub-portion 165. Each sub-portion 163, 165 may be referred to as a region. As shown in FIG. 14, the number of turns 113 per unit length of the first track 103 in the second separate portion 109 of the substrate 105 is different in the first sub-portion 163 compared to the second sub-portion 165. In the embodiment shown, the unit length of the first track 103 in the first sub-portion 163 exceeds the unit length of the first track 103 in the second sub-portion 165. The first sub-portion 163 comprises a first part 163a and a second part 163b. Furthermore, the number of turns 113 per unit length of the first track 103 between the first part 163a and the second part 163b varies, such that the unit length of the first track 103 in the second part 163b exceeds the unit length of the first track 103 in the first part 163a. ​​In other embodiments, the unit lengths of the first part 163a and the second part 163b may be equal. That is, the first part 163a and the second part 163a may be mirror images of each other. As shown in FIG. 14, the first track 103 in the first sub-portion 163 enters and exits the first sub-portion 163 at the same end. In other embodiments, the first sub-portion 163 may enter and exit at different ends or sides of the first sub-portion 163 or at one end and side of the first sub-portion 163. In this embodiment, the first track 103 of the sub-portion 163 effectively forms two columns and eight rows. In other embodiments, the first track 103 of the sub-portion 163 may form more than two columns and / or fewer than eight rows.

[0187] In this embodiment, the width of the second sub-portion 165 is greater than the width of the first sub-portion 163. Adjacent straight portions 167a-d are parallel to one another and are arranged in a row configuration. Each of the adjacent straight portions 167a-d has an equal width.

[0188] Referring to Fig. 15, a schematic diagram of a layered electrical configuration 1000 is shown. The layered electrical configuration 1000 comprises a first electrical configuration 101 corresponding to the electrical configuration 101 of Fig. 5 and a second electrical configuration 1101. The second electrical configuration 1101 comprises conductive tracks 1103, 1203 for the device 1 of Fig. 2. The second electrical configuration 1101 is arranged to be superimposed on the first electrical configuration 101 according to an embodiment of the present invention.

[0189] The second electrical component 1101 comprises a second substrate 1105 and a first outer track 1103 and a second outer track 1203. The second substrate 1105 is a structure configured to support the tracks 1103, 1203. The first outer track 1103 and the second outer track 1203 may be referred to as the third and fourth tracks, respectively. As indicated by the diagonal dashed lines, the second electrical component 1101 is intended to be combined with the first electrical component 101 by overlapping the second electrical component 1101 on top of the first electrical component 101. The first electrical component 101 and the second electrical component 1101 may be overlapped before being wrapped around the support tube 75 as a combination. The second electrical component 1101 comprises at least two separate portions 1107, 1109, 1111 in a first outer region 1106 and in a second outer region 1206 as shown in relation to the first electrical component 101. The first outer region 1106 and the second outer region 1206 may be referred to as third and fourth regions, respectively.

[0190] In other embodiments, the first outer path, shown as the first outer track 1103, and / or the second outer path, shown as the second outer track 1203, may be in the form of a conductive wire. In some embodiments, each wire is encapsulated by an electrically insulating element 103' instead of being formed on the second electrically insulating substrate 1105 as shown in and described above in connection with FIG. 4A. In this example, the structure 105' is provided by a component that is not the second electrically insulating substrate 1105. Such a construction may have any of the features described above in connection with FIG. 4A.

[0191] In this embodiment, the tracks 103, 203 on the first electrical component 101 are for performing a different one of a first and a second function with respect to the tracks 1103, 1203 on the second electrical component 1101. In this embodiment, the first electrical component 101 is for performing a first function of detecting the temperature of the heating zone 29 and the second electrical component 110 is for performing a second function of acting as a heating device for heating the heating zone 29 by resistive heating. The first electrical component 101 can therefore be referred to as a temperature sensor.

[0192] 16, there is shown a schematic cross-sectional view of an assembly 200 comprising substrate layers 1001, 1002 according to an embodiment of the present invention, each substrate layer 1001, 1002 comprising a conductive track for the device 1 of FIG. 2. Each substrate layer 1001, 1002 is a structural layer. The first substrate layer 1001 corresponds to the electrical component 101, and the second substrate layer 1002 corresponds to the second electrical component 1101. As shown in FIG. 16, the second substrate layer 1002 overlaps the first substrate layer 1001, and both substrate layers 1001, 1002 surround a third layer 1075 comprising the support tube 75. In other embodiments, the order of the substrate layers 1001, 1002 may be reversed, which is why the first substrate layer 1001 is provided above the second substrate layer 1002. In some embodiments, the conductive pathway is a conductive wire and is encapsulated by at least one electrically insulating element 103'. In such embodiments, the structure may be a component that is not an electrically insulating substrate.

[0193] Referring to FIG. 17, a schematic diagram of the second electrical component 1101 is shown. The second electrical component 1101 comprises two conductive tracks 1103, 1203 formed on an electrically insulating substrate 1105 offset by a gap 1169 substantially free of tracks. In this embodiment, the third track 1103 and the fourth track 1203 are wider than the first track 103 and the second track 203 because a higher current passes through the third track 1103 and the fourth track 1203 to establish a resistive heating effect. In other embodiments, the second electrical component 1101 may not be provided if the heating method used in another embodiment is, for example, induction heating. The third track 1103 and the fourth track 1203 are substantially mirror images of each other about the imaginary line CC. In other embodiments, a mirror image is not utilized.

[0194] 18, there is shown a schematic close-up view of the third track 1103. The third track 1103 comprises a number of turns 1113 and a straight section 1127. Additionally, similar to the first track 103, three separate portions 1107, 1109, 1111 are shown, each separated by gaps 1115, 1117.

[0195] The functionality of the first feature referenced above is discussed further below in relation to the first track 103 and the second track 203.

[0196] 2 is constructed and arranged to control the supply of power from the power source 27 to the first track 103 and the second track 203. The supply of power to each track 103, 203 is independent of each other when performing a first function.

[0197] A sensing device 83 senses the electrical resistance of each track 103,203.

[0198] The detection device 83 is configured to sample the electrical resistance of each of the first track 103 and the second track 203 for a predetermined duration. In this embodiment, the predetermined duration is about 250 μs (0.25 ms). In some embodiments, the predetermined duration is less than 1 ms. In some embodiments, the predetermined duration is less than 0.5 ms. In some embodiments, the predetermined duration is between 0.1 ms and 0.4 ms.

[0199] The detection device 83 is further configured to take a plurality of samples of the electrical resistance of each of the first track 103 and the second track 203 at a predetermined sampling rate (sometimes referred to as an interrupt rate). The frequency of the interrupt rate in this embodiment is about 100 Hz. In some embodiments, the frequency of the interrupt rate is less than 1 kHz. In some embodiments, the frequency of the interrupt rate is less than 500 Hz. In some embodiments, the frequency of the interrupt rate is between 1 Hz and 500 Hz. In some embodiments, the frequency of the interrupt rate is between 10 Hz and 200 Hz.

[0200] FIG. 19 is a diagram of a first circuit 300, which in this embodiment is used by the detection device 83 to sample the electrical resistance of the first track 103 at each predetermined duration. The circuit 300 comprises a first resistor 78 of known resistance R1, an electronic switch S1, and a first track 103, the entire first track 103 being arranged in electrical series with the switch S1 between the first resistor 78 and the first track 103. In this embodiment, the electronic switch S1 is an N-channel MOSFET, although any suitable electronic switch may be used. The first track 103 has a first end connected to a ground terminal and a second end connected to a source terminal of the MOSFET S1. A first resistor 78 has a first end connected to a drain terminal of the MOSFET S1 and a second end connected to a voltage Vp from the power supply 27. A control device 81 controls the gate terminal of MOSFET S1 using a control signal F1 to turn on MOSFET S1 for each predetermined duration (shown above) (e.g., 250 μs). When MOSFET S1 is on, a detection device 83 measures the voltage V at the second end of the first track 103 and determines the current through the circuit 300 (i.e., the current through the first resistor 78, MOSFET S1, and first track 103 to ground) according to Ohm's law using the following equation: Current = (Vp - measured voltage V) / R1 The detection device 83 determines a first resistance R2, which corresponds to the resistance of the first track 103, according to Ohm's law using the following formula: R2 = measured voltage V / current This calculation is based on the assumption that the resistance of MOSFET S1 is significantly smaller than the resistance R1 of first resistor 78 and can be safely ignored when calculating the current. Of course, the resistance of MOSFET S1 can be taken into account by simply adding the assumed value of this resistance to the resistance R1 of first resistor 78 in the formula used to calculate the current.

[0201] In some embodiments, the voltage Vp from the power supply 27 may vary and, rather than being held constant, must also be measured by the sensing device 31. In other embodiments, the voltage Vp from the power supply is held constant.

[0202] It should be appreciated that a corresponding second circuit (not shown) is used by the detection device 83 to determine a second resistance corresponding to the resistance of the second track 103 .

[0203] In some embodiments, depending on the measurement setup, the determined first and second resistances may actually include a contribution from the resistance of tracks outside both the first track 103 and the second track 203 individually (e.g. tracks included above the tail portion 73). By using predetermined information about the tracks outside the first track 103 and the second track 203, the detection device 83 or the control device 81 is configured to take into account the resistance caused by the tracks outside the first track 103 and the second track 203 to provide the final first and second resistances. That is, the detection device 83 or the control device 81 is configured to calculate the electrical resistance of a portion of the track in a direction away from the heating zone based on predetermined information about this portion. The predetermined information may include known physical information about the tracks outside the first track 103 and the second track 203, such as the known length, thickness and width of the track. In some embodiments, it may be assumed that the resistance of the tracks outside the first track 103 and the second track 203 is a fixed ratio to the total resistance, and that the detection device 83 may, in some cases, subtract this fixed ratio from the sum of the measured resistances to obtain the value of the resistance of the first track 103 and the second track 203. Once the resistance is known, the controller 81 is configured to calculate the temperature of each individual area using the temperature coefficient of resistance of the track and the known resistance of the individual tracks at known temperatures. For example, the temperature coefficient of resistance of copper at a known temperature of 20 degrees Celsius is 0.004041 per degree Celsius. The following equation is used to calculate the unknown temperature: R = Rref [1 + α (T - Tref)] where R=the unknown resistance of the track, Rref=the known resistance of the track at a known temperature, α=the temperature coefficient of the resistance of the track (e.g. copper), T=the unknown temperature of the track, and Tref=the known temperature when α is adopted.

[0204] As explained above, in some embodiments, the first outer track 1103 and the second outer track 1203 are superimposed on the first track 103 and the second track 203. In some embodiments, the first track 103 and the second track 203 are used in a first function and the first outer track 1103 and the second outer track 1203 are used in a second function. In such a situation, a correction factor may need to account for the temperature contribution by the second outer track 1203 to the tracks outside the first track 103, and specifically to the tail 73, due to the proximity of the tail 73 to the second outer track 1203 as shown in FIG. 15. Thus, a correction factor may be applied to the final first resistance to account for the temperature effect of the second outer track 1203 to the tracks outside the first track 103.

[0205] The correction includes determining a correction amount based on a temperature difference between the first outer region 1106 and the second outer region 1206. The correction amount is a reduction in the temperature of the first outer region 1106. The correction amount is calculated by applying a correction factor to the temperature difference. The correction factor may be about 90 millidegrees Celsius. Thus, for each degree Celsius of temperature difference, a reduction of 90 millidegrees Celsius is applied. The correction amount is the temperature difference in degrees Celsius multiplied by the correction factor. Reducing the detected temperature of the first outer region 1106 by the correction amount provides a more accurate temperature reading that accounts for the effect of the second outer track 1203 on the tracks outside the first track 103 and specifically on the tail 73 due to the proximity of the tail 73 to the second outer track 1203 as shown in FIG. 15. Thus, the temperature of the heated zone is calculated based on the electrical resistance of the track and the electrical resistance of the portion of the track away from the heated zone.

[0206] In some embodiments, the aerosol generating material is a non-liquid aerosol generating material and the device is for heating the non-liquid aerosol generating material for the purpose of volatilizing at least one component of the aerosol generating material.

[0207] With the exception of the etching process, any features described herein in relation to the formation of conductive tracks also apply to the embodiment in which the conductive pathways are conductive wires.

[0208] In some embodiments, the consumable 21 is an item that includes or is composed of an aerosol generating substance that is intended to be consumed in part or in its entirety by a user during use. Once all or substantially all of the volatilizable component(s) of the aerosol generating substance in the consumable 21 have been used, the user may remove the consumable 21 from the heating zone 29 of the device 1 and discard the consumable 21. The user may then reuse the device 1 with another consumable 21. However, in other particular embodiments, the consumable may be non-disposable, and the device and consumable may be discarded together after the volatilizable component(s) of the aerosol generating substance have been used.

[0209] In some embodiments, the consumables 21 are sold, supplied, or otherwise provided separately from the device 1, such that the consumables 21 are reusable with the device 1. However, in some embodiments, the device 1 and one or more of the consumables 21 may be provided together as a system, such as a kit or assembly, possibly with additional components such as a cleaning implement.

[0210] For the purpose of addressing various problems and advancing the art, the entire disclosure illustrates various embodiments by way of example and illustration, which may be used to practice the claimed invention, and further provide an improved heating element for use with an apparatus for heating an aerosol generating material, a method for forming a heating element for use with an apparatus for heating an aerosol generating material to volatilize at least one component of the aerosol generating material, and a system including an apparatus for heating an aerosol generating material to volatilize at least one component of the aerosol generating material and a heating element that can be heated by such an apparatus. The advantages and features of the disclosure are merely exemplary examples of embodiments and are not intended to be comprehensive and / or exclusive. The advantages and features of the disclosure are presented merely to aid in understanding and teaching the claimed features and other disclosed features. It is understood that the advantages, embodiments, examples, features, features, structures, and / or other aspects of the present disclosure are not to be construed as limitations on the disclosure as defined by the claims, or on the equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably include, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. The present disclosure may include other inventions not claimed in this document but which may be claimed in the future.

Claims

1. 1. An assembly for an aerosol delivery device for heating an aerosol generating material to volatilize at least one component of the aerosol generating material, comprising: a heating zone for receiving the aerosol generating material to be heated; Structure and at least one continuous conductive path supported by the structure configured to perform a first function of detecting a temperature of the heating zone based on an electrical resistance of at least one path and / or a second function of heating the heating zone by resistive heating; Equipped with the at least one path extends along at least two distinct portions of the structure; the at least one path comprises multiple turns in each of the at least two distinct portions of the structure; the at least two distinct portions of the structure are offset from one another by a gap that is substantially free of the at least one passage; the at least one path comprises a number of straight sections within each of the at least two separate portions of the structure, each straight section being interconnected by two turns of the number of turns; The multiple straight portions extend in the longitudinal direction of the heating zone. assembly.

2. 2. The assembly of claim 1, wherein adjacent edges of the at least one path are closer to each other within each of the at least two separate portions of the structure compared to adjacent edges of the at least one path between the at least two separate portions of the structure.

3. The assembly of claim 1 or 2, wherein adjacent ones of the multiple straight portions are spaced apart from one another by intervals having a size smaller than the gap.

4. The assembly according to any one of claims 1 to 3, wherein the size of the gap is less than twice the width of each straight portion.

5. The assembly of any one of claims 1 to 4, wherein any one of said multiple straight portions extends only partially around said heating zone.

6. 6. An assembly according to any one of claims 1 to 5, wherein the gap extends to at least one turn of the multiple turns within each of the at least two separate portions of the structure.

7. 7. An assembly according to any one of the preceding claims, wherein the at least two separate parts of the structure are arranged relative to each other in the longitudinal direction of the heating zone.

8. 8. The assembly according to claim 1, wherein a first width of the at least one path within at least one turn of the multiple turns is greater than a second width of the at least one path outside the at least one turn of the multiple turns.

9. The at least one pathway comprises a stress relief structure, the stress relief structure comprising: A first turn in a first direction followed by a second turn in a second direction Equipped with a length of the at least one path between the first turn and the second turn is less than a length of one of the first turn and the second turn; Assembly according to any one of the preceding claims.

10. 10. The assembly of claim 1, wherein the at least one pathway comprises a connecting portion that extends across the gap to connect the at least two separate portions of the structure.

11. The assembly of claim 10 , wherein the connecting portion comprises one turn of the multiple turns.

12. The assembly of claim 11 , wherein the connecting portion includes an inward turn that faces toward a center of the gap.

13. The assembly of claim 11 , wherein the connecting portion includes an outward turn that faces away from a center of the gap.

14. Assembly according to any one of claims 1 to 13, wherein the multiple turns comprise at least one 180 degree turn.

15. Assembly according to any one of claims 1 to 14, wherein the multiple turns comprise at least one semi-circular turn.

16. 16. The assembly of any one of claims 1 to 15, wherein the at least one path comprises a first portion and a second portion that extend to and traverse different respective sides of one of the at least two separate portions of the structure.

17. 17. The assembly of any one of claims 1 to 16, wherein a number of turns per unit length of the at least one path within one of the at least two separate portions of the structure is different in one region of the at least two separate portions of the structure compared to another region of the at least two separate portions of the structure.

18. 18. The assembly of claim 1, wherein the multiple turns within each of the at least one path form separate row arrays within the at least two separate portions of the structure and form columns within the at least two separate portions.

19. 19. The assembly of any one of claims 1 to 18, wherein the structure is or comprises at least one electrically insulating element, and the at least one continuous conductive path is a continuous conductive wire encapsulated by the at least one electrically insulating element.

20. Multiple continuous conductive paths Equipped with each of the first and second paths of the plurality of continuous conductive pathways extends along at least two separate portions of the structure in respective first and second regions; the first region and the second region are offset from one another by a gap that does not include any of the plurality of continuous conductive pathways. Assembly according to any one of the preceding claims.

21. 21. The assembly of claim 20, wherein the heating zones comprise a first heating zone and a second heating zone, the first path within the first region for performing the first and / or second functions associated with the first heating zone, and the second path within the second region for performing the first and / or second functions associated with the second heating zone.

22. 22. The assembly of claim 20 or 21, wherein the plurality of continuous conductive paths are supported by the same side of the structure.

23. 23. The assembly of any one of claims 20 to 22, wherein the structure is or comprises at least one electrically insulating element, and at least one continuous conductive path of the plurality of continuous conductive paths is a continuous conductive wire encapsulated by the at least one electrically insulating element.

24. Assembly according to any one of claims 1 to 18 and claims 20 to 22, wherein the structure is or comprises an electrically insulating substrate, and the at least one continuous conductive pathway is a continuous conductive track formed on the electrically insulating substrate.

25. a plurality of structures provided as a plurality of structural layers; a plurality of continuous conductive pathways, at least one continuous conductive pathway of the plurality of continuous conductive pathways being supported by a respective one of the plurality of structural layers; Equipped with each of the plurality of continuous conductive paths is for performing a different one of the first and second functions; Assembly according to any one of the preceding claims.

26. a plurality of structures provided as a plurality of structural layers; a plurality of continuous conductive pathways supported by a respective one of said plurality of structural layers; Equipped with a first path and a second path of the plurality of continuous conductive pathways are each supported by a first structural layer, and a third path and a fourth path of the plurality of continuous conductive pathways are each supported by a second structural layer; each of the first through fourth paths extending along at least two separate portions of the individual structures within respective first through fourth regions; each of the first and second regions on the first structural layer overlaps at least one of the third and fourth regions on the second structural layer; Assembly according to any one of the preceding claims.

27. 27. The assembly of claim 25 or 26, wherein at least one structure of the plurality of structures is or comprises an electrically insulating substrate, and at least one path of the plurality of continuous conductive paths is a continuous conductive track formed on the electrically insulating substrate.

28. 27. The assembly of claim 25 or 26, wherein at least one structure of the plurality of structures is or comprises at least one electrically insulating element, and at least one continuous conductive path of the plurality of continuous conductive paths is a continuous conductive wire encapsulated by the at least one electrically insulating element.

29. An assembly according to any one of claims 1 to 28, a controller for controlling the supply of power from a power source to the at least one continuous conductive pathway of the assembly; a detection device for detecting an electrical resistance of the at least one path; 1. An aerosol delivery device for heating an aerosol generating material to volatilize at least one component of the aerosol generating material, comprising:

30. 30. The aerosol delivery device of claim 29; a consumable including an aerosol generating material, the consumable being insertable into the heating zone of the assembly of the device; An aerosol delivery system comprising:

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