Electric electrode pin and a non-flammable aerosol delivery system including said electrode pin

Abstract

An electrode pin is provided comprising a first end, a second end, and at least one connecting portion between the first end and the second end, wherein the first end of the electrode pin includes one or more orientation features configured to orient the electrode pin into a specific rotational configuration when aligned with one or more alignment features of a corresponding component.

Description

Technology Field

[0001] The present invention relates to a delivery system, in particular to a non-combustible aerosol delivery system, and to components of said aerosol delivery system. The present invention also relates to methods for generating and delivering aerosols using the non-combustible aerosol delivery system and components disclosed herein. Background Technology

[0002] Non-flammable aerosol delivery systems for generating aerosols for inhalation by a user are known in the art. These systems typically include an aerosol generator capable of converting aerosolizable material into an aerosol. In some cases, the generated aerosol is a condensed aerosol, in which the aerosolizable material is first vaporized and then condensed into an aerosol. In other cases, the generated aerosol is an aerosol resulting from the atomization of the aerosolizable material. This atomization can be achieved mechanically, for example, by applying vibrations to the aerosolizable material to form small material particles mixed into the airflow. Alternatively, this atomization can be achieved electrostatically, or by other methods such as using pressure.

[0003] Since these aerosol delivery systems are intended to generate aerosols to be inhaled by the user, the characteristics of the generated aerosols must be considered. These characteristics may include the size of the aerosol particles and the total amount of aerosol generated.

[0004] In addition, since these aerosol delivery systems typically include storage areas for aerosolizable materials, methods for properly storing aerosolizable materials must be considered.

[0005] Furthermore, due to the popularity of these aerosol delivery systems, the ability to manufacture them efficiently is becoming increasingly important. Additionally, the systems must be robust enough to allow for multiple uses as needed.

[0006] It would be desirable to provide aerosol delivery systems having improvements related to one or more of the above modes of aerosol production, storage of aerosolizable materials, and manufacturing.

[0007] According to a first aspect of the present disclosure, an aerodynamically configured electrode pin is provided.

[0008] The electrode pin may include a first end, a second end, and at least one connecting zone between the first end and the second end, wherein at least one connecting zone is aerodynamically configured.

[0009] At least one connecting region may have an oval cross-section, an ellipsoidal cross-section, an aerofoil cross-section, a teardrop cross-section, or a polygonal cross-section when viewed along the longitudinal axis of the pin.

[0010] The first end can be configured to establish appropriate electrical contact with an aerosol generating component.

[0011] The first end of the electrode pin may include a collar.

[0012] The first end of the electrode pin may include one or more orientation features configured to orient the electrode pin into a specific rotational configuration when aligned with one or more alignment features of a corresponding component.

[0013] One or more orientation features can be notches.

[0014] One or more orientation features can be ribs.

[0015] The second end may include two retaining collars.

[0016] The two retaining collars can be spaced apart so that they span the wall of the outer housing component through which the electrode pin protrudes.

[0017] One or more sealing components may be provided at the interface between the retaining collars and the external housing components.

[0018] According to a second aspect of the present disclosure, an article for use as part of a non-combustible aerosol providing system is provided, the article comprises an aerosol generating component located at least partially within an aerosol generating chamber, wherein the article further comprises at least one electrode pin aerodynamically configured as defined according to the first aspect.

[0019] According to a third aspect of the present disclosure, a non-flammable aerosol providing system is provided, comprising an article according to a second aspect and a device comprising a power source and a control unit.

[0020] The device and the item can be connected detachably.

[0021] Devices and items can be permanently connected.

[0022] According to another aspect of the present disclosure, an electrode pin is provided comprising a first end, a second end, and at least one connecting portion between the first end and the second end, wherein the first end of the electrode pin comprises one or more orientation features configured to orient the electrode pin into a specific rotational configuration when aligned with one or more alignment features of a corresponding component.

[0023] One or more orientation features can be notches.

[0024] One or more orientation features can be ribs.

[0025] At least the connection zone can be aerodynamically configured.

[0026] At least one connecting section may have an oval cross-section, an ellipsoidal cross-section, an airfoil cross-section, a teardrop cross-section, or a polygonal cross-section when viewed along the longitudinal axis of the pin.

[0027] The first end can be configured to establish appropriate electrical contact with an aerosol generating component.

[0028] The first end of the electrode pin may also include a collar.

[0029] The second end may include two retaining collars.

[0030] The two retaining collars can be spaced apart so that they span the wall of the outer housing component through which the electrode pin protrudes.

[0031] One or more sealing components may be provided at the interface between the retaining collars and the external housing component.

[0032] The second end may include a connection surface configured to match the corresponding connection surface of the corresponding electrode.

[0033] The connecting surface of the second end may have a non-circular cross-section.

[0034] According to another aspect of the present disclosure, an article for use as part of a non-flammable aerosol providing system is provided, the article comprises an aerosol generating component located at least partially within an aerosol generating chamber, wherein the article further comprises at least one electrode pin as defined according to an aspect of the present disclosure.

[0035] According to another aspect of the present disclosure, a non-flammable aerosol providing system is provided, comprising an article according to an aspect of the present disclosure and a device comprising a power source and a control unit.

[0036] According to another aspect of the present disclosure, a non-flammable aerosol providing system is provided, comprising a device having a first pair of electrodes each having a connecting surface, and an article having a second pair of electrodes each having a connecting surface configured to match the corresponding connecting surface of the first pair of electrodes, wherein the cross-section of the connecting surface of at least one of the electrodes is different from the cross-section of another of the electrodes.

[0037] At least one of the electrodes may be as defined according to the first embodiment of the present invention.

[0038] Aspects of the present disclosure are set forth in the following provisions:

[0039] A1. An electrode pin comprising a first end, a second end, and at least one connecting section between the first end and the second end,

[0040] A first end of the electrode pin comprises one or more orientation features configured to orient the electrode pin into a specific rotational configuration when aligned with one or more alignment features of a corresponding component.

[0041] Electrode pin.

[0042] A2. In Clause A1, one or more orientation features are notches, electrode pins.

[0043] A3. In Clause A1, one or more orientation features are rib-ins, electrode pins.

[0044] A4. In any one of provisions A1 to A3, an electrode pin in which at least the connecting section is aerodynamically configured.

[0045] A5. In Clause A4, at least one connecting section is an electrode pin having an oval cross section, an ellipsoidal cross section, an airfoil cross section, a teardrop cross section, or a polygonal cross section when viewed along the longitudinal axis of the pin.

[0046] A6. In any one of provisions A1 through A5, an electrode pin, wherein the first end is configured to establish appropriate electrical contact with an aerosol generating component.

[0047] A7. In any one of provisions A1 to A5, the first end of the electrode pin comprises a collar.

[0048] A8. In any one of provisions A1 through A7, the second end comprises two retaining collars, an electrode pin.

[0049] A9. In Clause A8, the two retaining collars are spaced apart so that the electrode pin protrudes through the wall of the outer housing component.

[0050] A10. In Clause A9, an electrode pin, wherein one or more sealing components are provided at the interface between the retaining collars and the external housing component.

[0051] A11. An electrode pin, wherein, in any one of provisions A1 through A9, the second end comprises a connecting surface configured to match a corresponding connecting surface of a corresponding electrode.

[0052] A12. In Clause A11, the connecting surface of the second end has a non-circular cross-section, an electrode pin.

[0053] A13. An article intended for use as part of a non-flammable aerosol delivery system,

[0054] The article comprises an aerosol generating component located at least partially within an aerosol generating chamber, and the article further comprises at least one electrode pin specified in any one of provisions A1 to A12,

[0055] article.

[0056] A14. As a non-flammable aerosol supply system,

[0057] Articles of Clause A13, and devices including a power source and a control unit,

[0058] Non-flammable aerosol delivery system.

[0059] A15. As a non-flammable aerosol supply system,

[0060] A device having a first pair of electrodes each having a connecting surface, and an article having a second pair of electrodes each having a connecting surface configured to align with the corresponding connecting surface of the first pair of electrodes, wherein the cross-section of the connecting surface of at least one of the electrodes is different from the cross-section of another of the electrodes.

[0061] Non-flammable aerosol delivery system.

[0062] A16. In Clause A15, at least one of the electrodes is a non-flammable aerosol providing system as defined in any one of Clauses A1 to A12.

[0063] It will be understood that the features and aspects of the invention described above in relation to the first and other aspects of the invention are equally applicable to embodiments of the invention according to other aspects of the invention, and can be appropriately combined with embodiments of the invention according to other aspects of the invention, as well as with the specific combinations described above. Brief explanation of the drawing

[0064] Various embodiments will now be described in detail only by example with reference to the accompanying drawings: FIG. 1 is a schematic representation of an aerosol providing device according to the present disclosure. FIG. 2 is a schematic diagram of an article for an aerosol providing device according to the present disclosure. Figure 3 is an exploded view of the article of Figure 2. FIG. 4a is a cross-sectional view through the mouth-end portion of an article for an aerosol providing device according to the present disclosure. FIG. 4b is a perspective view of the article of FIG. 4a. FIG. 5 is an example of an article for an aerosol providing device according to the present disclosure. FIG. 6a is a cross-sectional view through the mouth-end portion of an article for an aerosol dispensing device according to the present disclosure. FIG. 6b is a cross-sectional view through the mouth-end portion of an article for an aerosol providing device according to the present disclosure. Fig. 6c is a cutaway perspective view of the article in Fig. 6b. FIG. 7a is an example of an article for an aerosol providing device according to the present disclosure. FIG. 7b is an example illustrating turbulence of air flow in a part of the article according to FIG. 3. FIG. 7c is an example illustrating turbulence of air flow in a part of the article according to FIG. 7a. FIGS. 8a and 8b are plan views along the longitudinal axis of an article for an aerosol providing device according to the present disclosure, which depict an arrangement comprising a plurality of air inlets in which the housing of the article is entirely within a perimeter defined by a heater. Fig. 8c is a cross-sectional view through the air inlets of Fig. 8b. FIG. 9 is a cross-sectional view of an aerosol generating chamber of an article for an aerosol providing device according to the present disclosure. FIG. 10 is an exploded view of a flow regulator and a second outer housing component of an article for an aerosol providing device according to the present disclosure. FIG. 11 is an electrode pin according to the present disclosure. FIG. 12a is a representation of the air flow velocity around an article comprising circular electrode pins according to the present disclosure. FIG. 12b is a representation of the airflow velocity around an article comprising aerodynamically configured electrode pins according to the present disclosure. FIG. 13 is a graphic representation of the effect on aerosol collection materials of the article according to FIG. 12a and, separately, the article according to FIG. 12b. Specific details for implementing the invention

[0065] Aspects and features of specific examples and embodiments are discussed and described herein. Some aspects and features of specific examples and embodiments may be implemented conventionally and are not discussed or described in detail for the sake of brevity. Accordingly, it will be understood that aspects and features of the discussed devices and methods that are not described in detail herein may be implemented according to any prior art for implementing such aspects and features.

[0066] As described above, the present disclosure relates to non-combustible aerosol delivery systems and devices that generate an aerosol from an aerosol-generating material (or aerosolizable material) without burning the aerosol-generating material (but are not limited thereto). Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (which generate an aerosol using a combination of aerosol-generating materials). In some examples, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vaping device or an electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement of the present disclosure. In some examples, the non-combustible aerosol delivery system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some examples, a non-combustible aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. In such a hybrid system, each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some examples, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or non-tobacco products.

[0067] Throughout the description below, the terms "e-cigarette" and "electronic cigarette" may be used from time to time; however, it will be understood that these terms may be used interchangeably with non-flammable aerosol (vapor) delivery systems or devices as described above.

[0068] In some examples, the present disclosure relates to consumables for holding aerosol-generating materials, configured to be used with non-flammable aerosol-providing devices. Such consumables are sometimes referred to as articles throughout the present disclosure.

[0069] A non-flammable aerosol delivery system typically includes a device part and a consumable / article part. The device part typically includes a power source and a controller. The power source can typically be an electric power source, such as, for example, a rechargeable battery.

[0070] In some examples, a non-flammable aerosol delivery system may include a consumable / article, an aerosol generator (which may or may not be located within the consumable / article), an aerosol generating area (which may be located within the consumable / article), a housing, a mouthpiece, a filter and / or an area for receiving or engaging with an aerosol modifier.

[0071] In some examples, consumables / articles for use with a non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area (or chamber), a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0072] The systems described herein typically generate an inhalable aerosol by vaporizing an aerosol generating material. The aerosol generating material may include one or more active ingredients, one or more flavors, one or more aerosol former materials, and / or one or more other functional materials.

[0073] The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, active substances and / or flavoring agents. In some examples, the aerosol-generating material may include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some examples, the amorphous solid may be a dried gel. An amorphous solid is a solid material capable of holding some fluid, such as a liquid, within it. In some examples, the aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% of an amorphous solid to about 90 wt%, 95 wt%, or 100 wt% of an amorphous solid.

[0074] As used herein, the term “active substance” may relate to a physiologically active material, which is a substance intended to achieve or enhance a physiological response. The active substance may be selected from, for example, health functional foods, nootropics, and psychotropic substances. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or their constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or other plants.

[0075] The aerosol former material may comprise one or more components capable of forming an aerosol. In some examples, the aerosol former material may comprise one or more of 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.

[0076] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0077] As used herein, the term “component” is used to refer to a part, section, unit, module, assembly, or similar of an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly within an external housing or wall. An electronic cigarette may be formed or constructed from one or more of these components, and the components may be removable or detachably connected to one another, or may be permanently joined together during manufacturing to define the entire electronic cigarette. The present disclosure is applicable to systems comprising two components that may be detachably connected to each other, for example (but not limited thereto), comprising a consumable / article component (also referred to herein as a cartridge or cartomiser) capable of holding an aerosol-generating material, and a device / control unit having a battery for providing electrical power to operate an element that generates vapor from the aerosol-generating material.

[0078] FIG. 1 is a very schematic drawing (not actual scale) of an exemplary aerosol / vapor delivery system such as an e-cigarette (10). The e-cigarette (10) generally has a cylindrical shape and extends along a longitudinal axis indicated by a dotted line and comprises two main components: a control or power component or section (20), and a cartridge assembly or section (30) that operates as a vapor generating component (also referred to as an article, consumable, cartomizer, or cartridge).

[0079] The cartridge assembly (30) comprises a storage compartment (3) comprising an aerosolizable material comprising a liquid formulation that generates an aerosol, for example, nicotine. For example, the aerosolizable material may comprise about 1 to 3 percent nicotine and 50 percent glycerol, with the remainder being approximately propylene glycol, and may also comprise other components such as water or flavoring agents. The storage compartment (3) takes the form of a storage tank and is a container or receptacle in which the aerosolizable material can be stored, allowing the aerosolizable material to move freely and flow (if liquid) within the boundaries of the tank. Alternatively, the storage compartment (3) may comprise a certain amount of absorbent material, such as cotton wadding or glass fiber, that holds the aerosolizable material within a porous structure. The storage compartment (3) may be filled during manufacturing and then sealed so that it becomes disposable after the aerosolizable material is consumed, or it may have an inlet port or other opening to add new aerosolizable material. The cartridge assembly (30) also includes an electric aerosol generating component (4) located outside the storage tank (3) to generate an aerosol by vaporizing the aerosolizable material. In many devices, the aerosol generating component may be a heating element (heater) that is heated by the passage of an electric current (through resistive or induction heating) to raise the temperature until the aerosolizable material evaporates. An array of liquid conduits, such as a wick or other porous element (not shown), may be provided to transfer the aerosolizable material from the storage compartment (3) to the aerosol generating component (4). The wick may have one or more parts located inside the storage compartment (3) so as to absorb aerosolizable material and transfer it to other parts of the wick that come into contact with the vapor generating element (4) by wicking or capillary action.Therefore, this aerosolizable material is vaporized and replaced with a new aerosolizable material that is transferred to the vapor generating element (4) by the wick.

[0080] A combination of a heater and a wick, or an array of other parts performing the same function, is sometimes referred to as a nebulizer or a nebulizer assembly. Various designs are possible in which the parts can be arranged differently compared to the very schematic representation in Fig. 1. For example, the wick may be a completely separate element from the aerosol generating component, or the aerosol generating component may be configured to be porous (e.g., by taking the form of a suitable electrically resistive mesh or capillary body) so as to perform the wicking function directly.

[0081] In some cases, the conduit for delivering the liquid for vapor generation may be formed at least partially with one or more slots, tubes, or channels between the storage compartment and the aerosol generating component, which are narrow enough to support capillary action to draw the source liquid from the storage compartment and deliver it for vaporization. Generally, the nebulizer may be considered as an aerosol generating component capable of generating vapor from the aerosolizable material delivered thereto, and as a liquid conduit (path) capable of delivering or transporting the liquid from the storage compartment or similar liquid reservoir to the aerosol generating component by capillary force.

[0082] Typically, an aerosol generating component is located at least partially within an aerosol generating chamber that forms part of an air flow channel passing through an electronic cigarette / system. Vapor generated by the aerosol generating component is discharged into this chamber, and as air passes through the chamber and flows over and around the aerosol generating component, the generated vapor is collected and consequently condensed to form the required aerosol.

[0083] Returning to FIG. 1, the cartridge assembly (30) also includes a mouthpiece (35) having an opening or air outlet through which a user can inhale an aerosol generated by an aerosol generating component (4) and delivered through an air flow channel.

[0084] The power component (20) includes a cell or battery (5) (hereinafter referred to as a battery, which may be rechargeable) for providing power to the electrical components of the e-cigarette (10), particularly the aerosol generating component (4). Additionally, there is a printed circuit board (28) and / or other electronic devices or circuits for generally controlling the e-cigarette. The control electronic devices / circuits connect the vapor generating component (4) to the battery (5) when vapor is needed, for example, in response to a signal from an air pressure sensor or air flow sensor (not shown) that detects inhalation on the system (10) where air is introduced through one or more air inlets (26) on the wall of the power component (20) and flows along an air flow channel. When the aerosol generating component (4) receives power from the battery (5), the aerosol generating component (4) vaporizes the aerosolizable material delivered from the storage compartment (3) to generate an aerosol, which is then inhaled by the user through the opening of the mouthpiece (35). As the user inhales from the mouthpiece (35), the aerosol is transported to the mouthpiece (35) along an air flow channel (not shown) connecting the air inlet (26) and the air outlet. Thus, the air flow path through the electronic cigarette is defined from the air inlet(s) (which may or may not be in the power component) to the atomizer and to the air outlet of the mouthpiece. In use, the direction of air flow along this air flow path is from the air inlet to the air outlet, and thus the atomizer can be described as being located downstream of the air inlet and upstream of the air outlet.

[0085] In this particular embodiment, the power section (20) and the cartridge assembly (30) are separate parts that are separable from each other by being separated in a direction parallel to the longitudinal axis, as indicated by the solid arrows in FIG. 1. The components (20, 30) are joined together by cooperative interlocking elements (21, 31) (e.g., screws, magnets, or bayonet fittings) that provide mechanical and electrical connections between the power section (20) and the cartridge assembly (30) when the device (10) is in use. However, this is merely an exemplary arrangement, and various components may be distributed differently between the power section (20) and the cartridge assembly section (30), and other components and elements may be included. The two sections may be connected end-to-end in a longitudinal configuration as in FIG. 1, or they may be connected in different configurations such as parallel or side-by-side arrangements. The system may or may not be generally cylindrical and / or may generally have a longitudinal shape. Either one or both sections may be intended to be discarded and replaced upon depletion (e.g., when the reservoir is empty or the battery is discharged), or may be intended to enable multiple uses through actions such as recharging the reservoir, charging the battery, or replacing the atomizer. Alternatively, the e-cigarette (10) may be a single device (disposable or rechargeable / rechargeable) that cannot be separated into two or more parts, in which case all components are contained within a single body or housing. Embodiments and examples of the present invention may be applied to any of these configurations and other configurations known to those skilled in the art.

[0086] As previously mentioned, the type of aerosol-generating component, such as a heating element that can be used in the spray portion of an electronic cigarette (the part configured to generate vapor from the source liquid), combines the functions of heating and liquid transfer by possessing both electrical conductivity (resistivity) and porosity. It should be noted here that the reference to electrical conductivity (resistivity) refers to components that have the capacity to generate heat in response to the flow of an internal electric current. This flow can be imparted through so-called resistance heating or induction heating. Examples of suitable materials include electrically conductive materials, such as metals or metal alloys, formed into sheet-like forms—that is, planar shapes with a thickness several times smaller than their length or width. In this regard, meshes, webs, and grills can serve as examples. Meshes can be formed by weaving metal wires or fibers together or, alternatively, by aggregating them into a non-woven structure. For example, fibers can be aggregated using a sintering method, in which heat and / or pressure are applied to a collection of metal fibers to compress them into a single porous mass. Planar aerosol generating components can define a curved plane, and in such cases, a reference to a planar aerosol generating component forming a plane refers to a hypothetical flat plane that forms the plane that best fits through the component.

[0087] These structures can provide capillary forces that wick liquids by offering appropriately sized voids and gaps between the metal fibers. Therefore, these structures may be considered porous structures because they provide liquid absorption and distribution. Additionally, because voids and gaps exist between the metal fibers, air can penetrate through these structures. Furthermore, since metals are electrically conductive, they are suitable for resistance heating, where an electric current flowing through a material with electrical resistance generates heat. However, this type of structure is not limited to metals; other conductive materials can be formed into fibers to manufacture mesh, grill, or web structures. Examples include ceramic materials that may or may not be doped with materials intended to match the physical properties of the mesh.

[0088] This type of flat sheet-type porous aerosol generating component can be arranged in an electronic cigarette so as to be placed within an aerosol generating chamber that forms part of an air flow channel. The aerosol generating component can be oriented within the chamber so that the airflow passing through the chamber flows toward the surface, that is, generally substantially parallel to the plane of the flat sheet-type aerosol generating component. Examples of such a configuration can be found in WO2010 / 045670 and WO2010 / 045671, the contents of which are incorporated herein by reference in their entirety. Then, as air flows over the heating element, steam can be collected. Thus, aerosol generation is achieved very effectively. In alternative examples, the aerosol generating component can be oriented within the chamber so that the airflow passing through the chamber flows in a direction substantially transverse to the surface, that is, generally in a direction substantially orthogonal to the plane of the flat sheet-type aerosol generating component. Examples of such configurations can be found in WO2018 / 211252, the contents of which are incorporated herein by reference in their entirety.

[0089] The aerosol generating component may have any one of the following structures: a woven or weave structure, a mesh structure, a fabric structure, an open-pore fiber structure, an open-pore sintered structure, an open-pore foam, or an open-pore deposition structure. The above structures are particularly suitable for providing an aerosol generating component having a high level of porosity. A high level of porosity can ensure that the heat generated by the aerosol generating component is primarily used to evaporate the liquid, and high efficiency can be obtained. Porosity exceeding 50% may be considered in the above structures. In one embodiment, the porosity of the aerosol generating component is 50% or more, 60% or more, or 70% or more. The open-pore fiber structure may be composed of, for example, a nonwoven fabric that can be arbitrarily compressed and may be additionally sintered to improve cohesion. The open-pore sintered structure may be composed of, for example, granular, fibrous, or cohesive sintered composites produced by a film casting process. Open-pore deposition structures can be produced, for example, by a CVD process, a PVD process, or flame spraying. Open-pore foams are commercially available in principle and can also be obtained with thin and fine pore designs.

[0090] In one embodiment, the aerosol generating component has at least two layers, wherein the layers comprise at least one of the following structures: a plate, a foil, paper, a mesh, a woven structure, a fabric, an open-pore fiber structure, an open-pore sintered structure, an open-pore foam, or an open-pore deposition structure. For example, the aerosol generating component may be formed by an electric heating resistor composed of a metal foil combined with a structure including a capillary structure. If the aerosol generating component is considered to be formed as a single layer, such a layer may be formed of a metal wire fabric or a non-woven metal fiber fabric. It is advantageous for the individual layers to be connected to each other through heat treatment such as sintering or welding, but they are not necessarily required to be connected. For example, the aerosol generating component may be designed as a sintered composite (e.g., AISI 304 or AISI 316 material) composed of one or more layers of stainless steel foil and stainless steel wire fabric. Alternatively, the aerosol-generating component can be designed as a sintered composite consisting of at least two layers of stainless steel wire fabric. These layers can be connected to each other by spot welding or resistance welding. Individual layers can also be mechanically connected to each other. For example, a double-layer wire fabric can be produced simply by folding a single layer. Instead of stainless steel, for example, heat conductor alloys with a much higher specific electric resistance than stainless steel—particularly NiCr alloys and CrFeAl alloys ("Kanthal")—may be used. Material bonding between the layers is achieved through heat treatment, so that the layers maintain contact with each other even under adverse conditions, such as when heated by the aerosol-generating component and consequently induced thermal expansions. Alternatively, the aerosol-generating component can be formed by sintering multiple individual fibers together.In this case, the aerosol generating component may consist of sintered fibers, such as sintered metal fibers.

[0091] The aerosol generating component may comprise an electrically conductive thin layer of an electrically resistive material, such as, for example, platinum, nickel, molybdenum, tungsten, or tantalum, said thin layer may be applied to the surface of the vaporizer by a PVD or CVD process or any other suitable process. In this case, the aerosol generating component may comprise an electrically insulating material, such as, for example, ceramic. Examples of suitable electrically resistive materials include stainless steels such as AISI 304 or AISI 316, and heat conductor alloys—in particular, NiCr alloys and CrFeAl alloys ("Kantal") such as DIN material numbers 2,4658, 2,4867, 2,4869, 2,4872, 1,4843, 1,4860, 1,4725, 1,4765, and 1,4767.

[0092] As described above, the aerosol-generating component can be formed from sintered metal fiber material and may be in the form of a sheet. This type of material can be conceived as a mesh or an irregular grid and is produced by sintering together a randomly aligned arrangement or array of spaced metal fibers or strands. A single layer of fibers may be used, or multiple layers, for example, up to five layers, may be used. For example, the metal fibers are arranged to provide a sheet with a diameter of 8 to 12 µm and a thickness of 0.16 mm, and 100 g / m² 2 Up to 1500 g / m² 2 , for example, 150 g / m² 2 Up to 1000 g / m² 2 , 200 g / m 2 Up to 500 g / m² 2 , or 200 to 250 g / m² 2The material density and can be spaced to produce 84% porosity. The sheet thickness may also be in the range of 0.1 mm to 0.2 mm, for example, 0.1 mm to 0.15 mm. Specific thicknesses include 0.10 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, or 0.1 mm. Generally, the aerosol generating component has a uniform thickness. However, it will be understood from the discussion below that the thickness of the aerosol generating component may also vary. This may be, for example, because some parts of the aerosol generating component have undergone compression. Different fiber diameters and thicknesses may be selected to vary the porosity of the aerosol generating component. For example, the aerosol-generating component may have a porosity of 66% or more, or 70% or more, or 75% or more, or 80% or more, 85% or more, or 86% or more.

[0093] The aerosol-generating component can form a generally flat structure comprising first and second surfaces. The generally flat structure can take the form of any two-dimensional shape, such as, for example, a circle, a semicircle, a triangle, a square, a rectangle, and / or a polygon. Generally, the aerosol-generating component has a uniform thickness.

[0094] The width and / or length of the aerosol-generating component may be about 1 mm to about 50 mm. For example, the width and / or length of the vaporizer may be 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. The width may generally be smaller than the length of the aerosol-generating component.

[0095] When an aerosol generating component is formed of an electrically resistive material, an electric current is allowed to flow through the aerosol generating component to generate heat (called Joule heating). In this regard, the electrical resistance of the aerosol generating component can be appropriately selected. For example, the aerosol generating component may have an electrical resistance of 2 ohms or less, e.g. 1.8 ohms or less, e.g. 1.7 ohms or less, e.g. 1.6 ohms or less, e.g. 1.5 ohms or less, e.g. 1.4 ohms or less, e.g. 1.3 ohms or less, e.g. 1.2 ohms or less, e.g. 1.1 ohms or less, e.g. 1.0 ohms or less, e.g. 0.9 ohms or less, e.g. 0.8 ohms or less, e.g. 0.7 ohms or less, e.g. 0.6 ohms or less, e.g. 0.5 ohms or less. Parameters of aerosol generating components, such as material, thickness, width, length, and porosity, can be selected to provide the desired resistance. In this regard, relatively lower resistance will facilitate higher power draw from the power source, which can be advantageous for generating a high rate of aerosolization. On the other hand, the resistance should not be so low as to compromise the integrity of the aerosol generator. For example, the resistance may not be lower than 0.5 ohms.

[0096] Planar aerosol generating components, such as heating elements suitable for use in the systems, devices, and articles disclosed herein, may be formed by stamping or cutting (e.g., laser cutting) the required shape from a larger sheet of porous material. This may include stamping, cutting, or otherwise removing the material to create openings in the aerosol generating component. These openings may affect the ability of air to pass through the aerosol generating component and the tendency of electric current to flow in specific areas.

[0097] FIG. 2 illustrates an exemplary article (100) according to the present disclosure. The article (100) comprises an outer housing (110), which in this example is formed by the combination of first and second outer housing components (110a and 110b). The specific appearance of the outer housing (110) is not limited, but in the example of FIG. 2, the outer housing (110) has a multi-faceted surface. The outer housing (110) comprises at least one outlet (115). As illustrated in the example of FIG. 2, there may be two outlets. The outlet (115) is intended to transport an aerosol generated within the article (100) to the user's mouth. Thus, in the example illustrated in FIG. 2, the outer housing (110) also forms a mouthpiece of the article.

[0098] The first outer housing component (110a) is fitted with the second outer housing component (110b) to form the outer housing (110). In the example illustrated in FIG. 2, the components are fitted to each other via a snap-fit ​​arrangement. In particular, elastic tabs (111) on the outer housing component (110b) (only one side of which is visible in FIG. 2) are snapped into corresponding receiving holes (112) on the outer housing (110a). The exact location of the tabs and holes is not limited, and it will be seen that, in practice, the tabs can be formed on the outer housing component (110a) and the holes on the outer housing component (110b).

[0099] FIG. 3 shows an exploded view of the exemplary article (100) of FIG. 2. In particular, the outer housing component (110a) is shown separated from the outer housing component (110b) to expose the inner housing component (120), the aerosol generating component (130, which is an electric resistive metal heater in this example), the flow regulator (140), and the pad (150). The inner housing component (120) is configured to define a storage area (121) for aerosolizable material (not shown). The inner housing component (120) is at least partially sleeved inside the outer housing component (110a). The inner housing component (120) may be connected to the outer housing component (110a) (for example, they may be attached together as shown in FIG. 6c or be the same molded part). The inner housing component (120) has an open end (122) that aligns with the flow regulator (140). The open end (122) and the flow regulator (140) together allow aerosolizable material Defines a path flowing from the storage area (121) to the pad (150). An optional mouthpiece (not shown) may be sleeved over the outside of the outer housing component (110a) (or the outer housing may form the mouthpiece).

[0100] The flow regulator (140) includes a recess (141) in which an open end (122) of an internal housing component (120) can be received. The recess (141) may include one or more openings (142) that allow the flow of aerosolizable material through the flow regulator. In the example of FIG. 3, the openings are slot-shaped, but it will be understood that one or more of the openings may take different cross-sections, such as circular, elliptical, or polygonal. Additionally, the cross-sectional area of ​​one or more openings may vary depending on the length of the flow regulator. Thus, one or more openings may have a larger cross-sectional area at a location facing the liquid storage area compared to the cross-sectional area at a location facing the pad (150). The flow regulator (140) also includes an annular seal (143) around its circumference that serves to suppress the discharge of aerosolizable material from the boundary between the inner housing component (120) and the flow regulator (140). The flow regulator (140) also includes a surface to which the aerosol generating component can be deflected, and thus serves as a heater support in some cases.

[0101] The pad (150) can be formed of a capillary material suitable for holding aerosolizable material. In particular, when the aerosolizable material flows through the flow regulator (140), the pad (150) becomes saturated with the aerosolizable material. However, due to the capillary properties of the pad (150), leakage of the aerosolizable material from the pad (150) is suppressed. Since the aerosol generating component (130) is positioned in close proximity to the pad (150), when energy is supplied to the aerosol generating component (130) (in this case, resistance heating), the aerosolizable material present in the pad (150) is vaporized. As described above, the pad (150) and the aerosol generating component (130) are expected to be combined into a single component.

[0102] The aerosol generating component (130) is arranged toward the outer housing component (110b). Electrical pins (116) on the outer housing component (110b) contact the aerosol generating component (130) at taps (131) to allow an electric current to flow through the aerosol generating component (130) during the operation of the system. The outer housing component (110b) includes at least one air inlet (117) to allow air to be introduced into the article (100). During use, air is introduced into the article (100) through at least one air inlet (117) and mixed with vapor generated from the aerosol generating component (130). The generated aerosol is then directed to one or more air outlets (115) through at least one channel (160) (not shown) extending between the outer housing component (110a) and the inner housing component (120). For example, in the embodiment of FIG. 2, there are two channels (not shown) that extend longitudinally along the length of the article (100) and work in conjunction with air outlets (115) to create a flow path through the article.

[0103] According to one embodiment, the outer housing and the inner housing may include individual stabilizing surface features that interact with each other. These surface features enable the creation of housing walls that are relatively thin yet sufficiently resilient so that the channels for the aerosol passages described above do not collapse. For example, an article for use as part of a non-flammable aerosol delivery system is disclosed, which comprises an outer housing that surrounds at least a portion of the inner housing such that an air flow channel exists between the outer housing and the inner housing, wherein one of the outer housing and the inner housing comprises a surface feature configured to align with a corresponding surface feature of the other of the outer housing and the inner housing.

[0104] FIG. 4a provides a cross-sectional view through the mouth-end portion of an article (200) according to the present disclosure. FIG. 4b shows a perspective view of the cross-sectional view of FIG. 4a. The article (200) includes an outer housing component (210) and an inner housing component (220). As with the example of FIG. 2, the inner housing component (220) is configured to define a storage area for an aerosolizable material. The inner housing component (220) is sleeved within the outer housing component (220) so that an air flow channel (260) is formed between the opposing walls of the outer housing and the inner housing. The channel (260) extends from an air inlet (not shown) into the article (200) to an air outlet (215). According to the example of FIG. 4a, the inner housing component (220) includes a surface feature (226) configured to align with a corresponding surface feature (216) of the outer housing component (210). According to the example of FIG. 4a, the surface feature (226) is formed by two protrusions (226a and 226b). These protrusions are spaced apart to provide a receiving gap for the surface feature (216) of the outer housing component (210). In some examples, each surface feature has a height substantially equal to the distance between the opposing walls of the inner and outer housings forming the channel (260). Consequently, the surface features serve to provide support for each of the individual housings. For example, the surface features can prevent or reduce the wall of the outer housing component (210) from being compressed into the channel (260). This ensures that the channel dimensions are more stable during use. Additionally, due to the cooperative nature of the individual surface features, lateral movement of the housings relative to each other can be reduced. Therefore, surface features can provide a more robust article, and also facilitate the use of less material to form housings (since the walls can be thinner), and can provide a more consistent airflow through the device.

[0105] It should be understood that the exact configuration of surface features may vary depending on the overall shape of the article. For example, each surface feature may include at least one protrusion. Each surface feature may include more than one protective portion. Surface features of either the outer housing or the inner housing may include more protrusions than surface features of the other housing. Surface features of the outer housing may be located near at least one exit of the outer housing. The protrusions of the surface features may extend substantially along the longitudinal axis of the article. Each surface feature may be formed with one, two, three, four, or more protrusions. If the housing includes a surface feature having more than one protrusion, these protrusions may be arranged in-line or offset with respect to the longitudinal section, that is, at least one protrusion is on a different side of the section. Surface features are generally formed when the housings are molded and are therefore formed from the same material as the housing. Suitable materials for this purpose include plastics such as polypropylene or polycarbonate. Alternatively, surface features can be formed via a two-shot process and may be made of materials different from the housing. The use of surface features allows for a reduction in the thickness of the housing walls, which can lead to cost savings. Additionally, if the plastic is transparent, it can be advantageous as it provides the user with a clearer indication of the amount of aerosolizable material in the storage area.

[0106] According to one embodiment, a plurality of air flow channels feed dedicated air outlets of the article. For example, an article for use as part of a non-flammable aerosol delivery system is disclosed, wherein the article comprises an outer housing that surrounds at least a portion of an inner housing, and a plurality of individual air flow channels are provided between the inner housing and the outer housing, each air flow channel extends to a corresponding air outlet of the outer housing. This may be advantageous in that a reduced aerosol density along each channel can be maintained to the outlet of the article. This may help to prevent aerosol condensation within the channels and / or at the outlet, thereby reducing the possibility of leakage of condensed aerosol, which could cause discomfort to the user as the condensed aerosol leaks from the article.

[0107] FIG. 5 provides an example of another exemplary embodiment of the present disclosure. In particular, FIG. 5 illustrates an article (300) comprising an outer housing component (310a) and an outer housing component (310b). As described in relation to article (100), article (300) also comprises an inner housing component (320) that is sleeved at least partially within the outer housing component (310a) (not shown in FIG. 5). Outlets (315a and 315b) are present in the outer housing component (310a). Each outlet is fluidly connected to a dedicated air flow channel (360a and 360b) (not shown in FIG. 5). In a manner similar to that described in article (200), the air flow channels (360a and 360b) extend longitudinally along the article between the outer housing component (310a) and the inner housing component (320). However, while individual channels in article (200) meet at a single location (outlet (215)), in the example of FIG. 5, the air flow channels (360a and 360b) do not meet and instead feed exclusively to the respective outlets (315a and 315b). This can be more easily identified in the schematic examples of FIG. 6a and 6b corresponding to cross-sections through article (300). As can be seen in FIG. 6a, the air flow channels (360a and 360b) do not meet and instead feed exclusively to the respective outlets (315a and 315b). This exclusivity is created by the presence of a dividing wall (317) separating the individual flow channels. As illustrated, the outlets in this example may take the form of slots. As the air flow channels (360a and 360b) approach the slotted outlets (315a and 315b), the channel height can be progressively reduced. That is, the slotted outlets can each be fed through inclined surfaces (318a / 318b).These sloped surfaces have the advantage of being able to guide any aerosol condensate formed at or near the outlet into individual feeding channels (360a / 360b). Additionally, the sloped surfaces can provide a smoother flow path from the outlet compared to more turbulent scenarios that may be created when two opposing channels meet, or when the channels (360a / 360b) end more abruptly (as in FIG. 6a). The slope of the incline can generally be defined relative to the plane of the outlet (shown as a dashed line in FIG. 6b). In some examples, the slope is between 10° and 45°.

[0108] If the outlets are composed of slots, they may have a length of at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, or at least 10 mm.

[0109] FIG. 6c illustrates a cross-sectional view of an article (300) as depicted in FIG. 6b (parts of the article not mentioned in the context of FIG. 6b are not labeled in relation to FIG. 6c). As can be seen in FIG. 6c, the outlets of this example may take the form of slots. As the air flow channel (360b) (outlet (360a) is not shown in FIG. 6c) approaches the slotted outlet (315b), the slotted outlet is fed through an inclined surface (318b). This inclined surface has the advantage of being able to guide any aerosol condensate formed at or near the outlet into the individual feeding channel (360b). Additionally, the inclined surface may provide a smoother flow path from the outlet compared to more turbulent scenarios that may exist where two opposing channels meet, or where the channels (360a / 360b) end more abruptly (as in FIG. 6a). As mentioned above, the slope of the incline can generally be defined with respect to the plane of the exit (shown by the dashed line in Fig. 6b). In some examples, the incline is 10° to 75°. In some examples, the incline is 10° to 65°. In some examples, the incline is 10° to 55°. In some examples, the incline is 10° to 45°. In some examples, the incline is 15° to 75°. In some examples, the incline is 25° to 75°. In some examples, the incline is 35° to 75°. The inclined surface may take a curved profile, for example, it may have a convex or concave profile.

[0110] In some embodiments, the dimensions of the airflow channel existing between the outer housing and the inner housing are carefully controlled to promote laminar airflow along the channel. In particular, the distance (d1) between the opposing walls of the outer housing component and the inner housing component in one section along the airflow channel and the distance (d2) between the opposing walls of the outer housing component and the inner housing component in any other section along the airflow channel may vary such that (d2-d1) / d1 x 100 is less than 10%. This helps ensure that turbulence does not increase as the airflow flows through the channel.

[0111] FIG. 7a provides an example of another exemplary embodiment of the present disclosure. In particular, FIG. 7a illustrates an article (300) comprising an outer housing component (310) and an inner housing component (320). Air flow channels (360a and 360b) extend longitudinally between the walls of the outer housing component (310) and the inner housing component (320). In particular, the air flow channels (360a and 360b) extend between their individual outlets (315a and 315b) and the aerosol generating chamber (348). Thus, each air flow channel (360a, 360b) forms a path through which an aerosol can be transported from the aerosol generating chamber to its individual outlet. Each air flow channel may include a longitudinal section (361a, 361b) and a lateral section (362a, 362b). The longitudinal section is generally parallel to the longitudinal axis of the article, and the lateral section is generally perpendicular to the longitudinal axis of the article. The longitudinal and lateral sections of each channel may meet at a joint section (363). The longitudinal section is generally longer than the lateral section. For example, the longitudinal section may account for more than 50%, more than 60%, more than 70%, more than 80%, or more than 90% of the total length of the air flow channel (the length contributed by the joint section is discounted to determine the relative proportion of contribution). The joint section may have a bend of 80° to 100°, for example, about 90°.

[0112] In one embodiment, the variation between the deepest and shallowest sections along the opposing walls of the outer and inner housing components defining the longitudinal sections (361a and 361b) of the airflow channel is 10% or less at any point along the longitudinal sections of the airflow channel. For example, d1 is the distance between the opposing walls of the outer and inner housing components in the first section along the airflow channel, and d2 is the distance between the opposing walls of the outer and inner housing components in the second section along the airflow channel, and (d2 - d1) / d1 x 100 < 10%. In some embodiments, (d2 - d1) / d1 x 100 < 9%. In some embodiments, (d2 - d1) / d1 x 100 < 8%. In some embodiments, (d2 - d1) / d1 x 100 < 7%. In some embodiments, (d2 - d1) / d1 x 100 < 6%. In some embodiments, (d2 - d1) / d1 x 100 < 5%.

[0113] By controlling the depth of the longitudinal section of the airflow channel to be very constant, the tendency for condensation to form within the longitudinal section can be reduced.

[0114] In one embodiment, the external profile of the article (which may be formed by an external housing component or a mouthpiece sleeved over the external housing component) tapers toward the proximal end of the article (the proximal end is the end where the aerosol outlets are located). This tapering is advantageous for facilitating a more ergonomically designed mouthpiece. However, if there are multiple airflow channels positioned on both sides of the internal housing component, this tapering may lead to corresponding tapering of the airflow channels. In this embodiment, significant tapering of the airflow channels is avoided.

[0115] In some examples, the profiles of one or more airflow paths from the aerosol generating chamber to the outlet are configured to reduce the formation of condensation. Accordingly, in one embodiment, an article for use as part of a non-combustible aerosol supply system is provided, wherein the article comprises at least one aerosol outlet and at least one airflow channel, wherein the at least one aerosol outlet is arranged to be in fluid communication with at least one airflow channel, wherein the at least one airflow channel has longitudinal and lateral sections connected together through a joint section, wherein the joint section has a curved outer wall. Without being bound by theory, it is understood that the curved outer wall reduces turbulent airflow and increases laminar airflow as the airflow (and thus the aerosol in use) moves around the joint section. This, in turn, leads to a reduction in the formation of condensation within the article.

[0116] Referring again to FIG. 7a, an article (300) comprising an outer housing component (310) and an inner housing component (320) is illustrated. Air flow channels (360a and 360b) extend longitudinally between the walls of the outer housing component (310) and the inner housing component (320). In particular, the air flow channels (360a and 360b) extend between their individual outlets (315a and 315b) and the aerosol generating chamber (348). Thus, each air flow channel (360a, 360b) forms a path through which an aerosol can be transported from the aerosol generating chamber to its individual outlet. Each air flow channel may include a longitudinal section (361a, 361b) and a lateral section (362a, 362b). The longitudinal section is generally parallel to the longitudinal axis of the article, and the lateral section is generally perpendicular to the longitudinal axis of the article. The longitudinal and lateral sections of each channel may meet at a joint section (363). The longitudinal and lateral sections are generally longer than the lateral sections. For example, the longitudinal section may account for more than 50%, more than 60%, more than 70%, more than 80%, or more than 90% of the total length of the air flow channel (the length contributed by the joint section is discounted to determine the relative proportion of contribution).

[0117] Now, the joint section (363) will be further described. The joint section (363) includes an inner wall section (363a) (located at the apex of the joint) and an outer wall section (363b). The outer wall section (363) is formed as a curved outer wall. In contrast to the outer wall configuration of the joint section shown in FIG. 3, where the entire exterior of the joint section is formed of intersecting linear walls rather than a curved outer wall, the reference to the outer wall of the joint section refers to a section of the air flow channel rather than the outer surface of the outer housing.

[0118] The effect of configuring the joint section to have a curved outer wall can be seen by comparing the images in FIG. 7b and FIG. 7c. In FIG. 7b, when the joint section is formed as shown in the embodiment of FIG. 3, turbulence increases when airflow and aerosols are transferred through the joint section. In contrast, when the joint section has a curved outer wall as shown in FIG. 7c, turbulent airflow is reduced.

[0119] In some examples, and as described above, there are at least two air flow channels, each including at least one joint section having a curved outer wall.

[0120] In some examples, there is an additional joint section connecting a longitudinal section of the airflow channel and at least one aerosol outlet of the article. This additional joint section may also have a curved outer wall.

[0121] In some examples, the location of air inlets into the article must be controlled to ensure alignment with the aerosol generating component. In one embodiment, an article for use as part of a non-flammable aerosol delivery system is provided, the article comprises a housing and a substantially planar aerosol generating component, wherein the housing comprises a plurality of air inlets disposed within a first plane of a first end, wherein the aerosol generating component forms a second plane, wherein the plurality of inlets are entirely within the perimeter defined by the aerosol generating component when viewed along an axis perpendicular to the first plane. In some embodiments, the second plane is slightly angled with respect to the first plane. For example, the second plane may be angled with respect to the first plane up to 15 degrees, up to 10 degrees, up to 8 degrees, up to 5 degrees, or up to 2 degrees. In some embodiments, the second plane is substantially parallel to the first plane.

[0122] Multiple inlets may exist entirely within the perimeter defined by the aerosol generating component when viewed along an axis perpendicular to the first and second planes.

[0123] As described above, with reference to FIG. 3, the aerosol generating component (130) is arranged toward the outer housing component (110b). Electrical pins (116) on the outer housing component (110b) contact the aerosol generating component (130) at taps (131) so that an electric current can flow through the aerosol generating component (130) during operation of the system. The outer housing component (110b) includes at least one air inlet (117) that allows air to enter the article (100). During use, air is introduced into the article (100) through at least one air inlet (117) and mixed with vapor generated from the aerosol generating component (130). The generated aerosol is then directed to one or more air outlets (115) through at least one channel (160) (not shown) extending between the outer housing component (110a) and the inner housing component (120).

[0124] As illustrated in FIG. 3, a plurality of air inlets (117) exist. In the example of FIG. 3, there are six air inlets, but it is considered that there may be two, three, four, five, six, seven, or eight air inlets. Each air inlet extends directly from the outside of the article (100) into the aerosol generating chamber (148). Each air inlet (117) may extend through the second outer housing component (110b). The aerosol generating chamber (148) may be formed by a surface facing inward of the second outer housing component (110b) and a flow component (140). The aerosol generating component (130) is located within the chamber (148) formed by the combination of the second outer housing component (110b) and the flow component (140).

[0125] FIGS. 8A and 8B illustrate an arrangement comprising a plurality of air inlets that are entirely within the perimeter defined by the heater when the housing of the article is viewed along the longitudinal axis. In particular, FIG. 8A illustrates a top view of the aerosol generating component (130) of FIG. 1. As described above, the aerosol generating component (130) includes tap sections (131) that serve to contact the electrical pins (116) of the article to allow current to flow through the aerosol generating component (130). The aerosol generating component (130) includes a heated section (132). The heated section is generally defined by a temperature perimeter within 10% of the portion of the heater that has the highest temperature during normal use. That is, the corresponding areas where the temperature of the heater drops to less than 10% of the highest temperature experienced by the heater during normal use are outside the perimeter of the heated section.

[0126] In the examples of FIGS. 3 and FIGS. 8a, the heated section (132) comprises a number of parallel filament sections (132a) separated by corresponding parallel spaces. Because their width is reduced, the sections (132a) have relatively higher resistance and therefore experience greater heating when current flows through them. As a result, the heater is generally heated to a higher temperature within the heated section (132) containing the filaments. It is advantageous for the openings of the airflow inlets (117) leading to the aerosol generating chamber to be concentrated within the perimeter of the heater, particularly within the perimeter of the heated section (132). An example of this can be seen in FIG. 8a, which is a schematic plan view of the contour of the heated section (132) overlaid on the plan view of the airflow inlets (117). As can be seen, the airflow inlets (117) are located within the perimeter of the heated sections. The air flow inlets (117) can be distributed in various ways within the circumference of the heater. For example, if there are 2 to 6 air inlets, they can be configured as found in a die.

[0127] FIG. 8c illustrates a cross-sectional view through an air inlet (117) extending through a second outer housing component (110b). As illustrated in FIG. 8c, each air inlet (117) has an opening (117a), a neck section (117b), and an outlet (117c). The opening and outlet sections of each air inlet may have the same shape and / or dimensions, or they may have different shapes and / or dimensions. The neck section (117b) extends between the opening and outlet sections of each air inlet. If the size and shape of the opening and outlet sections are different, the shape of the neck sections will also be different. For example, by changing the shape of the opening and outlet sections, the flow passing through the neck section of the air inlet can be changed. In one embodiment, the opening and outlet sections of at least one air inlet are all the same. In one embodiment, the opening and outlet sections of at least one air inlet are all different. In one embodiment, the opening and outlet sections of at least one air inlet both have a circular shape. In one embodiment, the opening and outlet sections of at least one air inlet both have an elliptical shape. In one embodiment, the opening and outlet sections of at least one air inlet both have a slot shape. In one embodiment, the opening and outlet sections of at least one air inlet both have a polygonal shape.

[0128] Likewise, the flow through the air inlet can be changed by altering the dimensions of the opening and outlet sections. In one embodiment, the opening and outlet sections of at least one air inlet have the same cross-sectional area. In one embodiment, the opening and outlet sections of at least one air inlet have different cross-sectional areas. In one embodiment, the opening has a smaller cross-sectional area than the outlet section. In one embodiment, the opening has a larger cross-sectional area than the outlet section.

[0129] In one embodiment, at least two of the plurality of air inlets share a neck portion of the same size and shape. In one embodiment, at least three of the plurality of air inlets share a neck portion of the same size and shape. In one embodiment, at least four of the plurality of air inlets share a neck portion of the same size and shape. In one embodiment, at least five of the plurality of air inlets share a neck portion of the same size and shape. In one embodiment, at least six of the plurality of air inlets share a neck portion of the same size and shape. In one embodiment, all of the plurality of air inlets share a neck portion of the same size and shape.

[0130] In some examples, it is advantageous that the aerosol generating component can be maintained in place in a simple and convenient manner. In particular, in some embodiments, an article for use as part of a non-flammable aerosol delivery system is provided, the article comprises an external housing component coupled to a heater support, wherein the external housing component has at least one protrusion comprising a surface shaped to deflect a substantially flat aerosol generating component against a corresponding surface on the heater support when the external housing component is coupled to the heater support.

[0131] FIG. 9 provides a cross-sectional view through the aerosol generating chamber (148) when the article is in its assembled form. As can be seen, the aerosol generating component (130) is positioned together with the aerosol generating chamber (148) formed by the flow regulator (140) and the second outer housing component (110b) (or end cap). An enclosure (149) is located on the surface protruding inwardly from the second outer housing component (110b). The enclosure (149) is partially formed by one or more perimeter walls (149a). One or more perimeter walls (149a) have a perimeter edge (149b). This perimeter edge (149b) includes at least one retaining feature (149c). The at least one retaining feature is configured to be aligned with a corresponding retaining feature (147) on the flow regulator (140). When the flow regulator (140) and the second outer housing component (110b) are combined, the aerosol generating component (130) is sandwiched between them. Thus, the flow regulator acts as a heater support. At least one holding feature (149c) on the peripheral edge (149b) and at least one holding feature (147) on the flow regulator (140) are interlocked to hold the aerosol generating component (130) in place. The peripheral edge (149b) has a surface (149d) that is coplanar with the corresponding forming surface (142) of the flow regulator (140). Due to the coplanar nature of the surface (149d) and the forming surface (142), the aerosol generating component (130) is deflected and held in that same plane. Accordingly, by configuring the planes of the individual surfaces (149d) and the forming surface (142), the shape of the aerosol generating component (130) can be influenced. In this particular embodiment, the flow regulator acts as a heater support. However, in other embodiments, the heater support may be performed by other components of the article that do not act as a flow regulator.

[0132] In one embodiment, the plane formed between at least one surface of the peripheral edge and at least one forming surface of the flow regulator is curved. In one embodiment, the plane formed between at least one surface of the peripheral wall and at least one forming surface of the flow regulator is convex when viewed from the perspective of the external housing component. In one embodiment, the plane formed between at least one surface of the peripheral wall and at least one forming surface of the flow regulator is concave when viewed from the perspective of the external housing component.

[0133] Additional examples of the flow regulator and the second outer housing component are illustrated in FIG. 10. In particular, FIG. 10 illustrates an exploded view of the flow regulator (440) and the second outer housing component (410b). The aerosol generating component (130) and the pad (150) are as described in relation to other examples and will not be described further here.

[0134] The flow regulator (440) includes a recess (141) in which an open end (122) of an inner housing component (120) can be received (not shown). The recess (441) may include one or more openings (442) that allow the flow of aerosolizable material through the flow regulator. The flow regulator (440) also includes an annular seal (443) around its perimeter that serves to suppress the discharge of aerosolizable material from the boundary between the inner housing component (420) and the flow regulator (440). The flow regulator (440) includes at least one retaining feature (447), which is configured to interact with a corresponding retaining feature (449c) of the second outer housing component on the second outer housing component (410b). In one embodiment, the flow regulator includes one, two, three, four, or more retaining features. In one embodiment, the second outer housing component (410b) includes a corresponding number of retaining features as in the flow regulator. In the example of FIG. 10, the flow regulator includes four retaining features (447) (only two of which are shown). Each of these retaining features is a tab extending laterally. When the flow regulator and the second outer housing component (410b) are combined, the corresponding retaining features (449c) on the second outer housing component (410b) are interlocked with the tabs of the retaining features (447). In particular, the corresponding retaining features (449c) on the second outer housing component (410b) include upright teeth having inclined ridges (449e) protruding toward the retaining features (447). The inclined ridge (449e) goes up over the tab of the corresponding holding feature (447), and then when the ridge passes the tab, it snaps into place to lock the second outer housing component (410b) to the flow regulator (140).

[0135] The second outer housing component (410b) also includes one or more perimeter walls (449a). One or more perimeter walls (449a) of the second outer housing component (410b) have a forming surface (449d) (only one of which is visible in FIG. 10). The forming surface (449d) works in conjunction with a corresponding forming surface (not visible in FIG. 10) on the flow regulator (440) and operates as previously described in relation to the example in FIG. 9.

[0136] The flow regulator (440) also includes a skirt (446) accommodated by a second outer housing component (410b). The skirt (446) extends laterally from the flow regulator (440) and serves as an outlet for an aerosol generating chamber (448) formed by the combination of the flow regulator (440) and the second outer housing component (410b).

[0137] As described above, the articles described herein generally comprise at least one, typically two, electrode pins. These are illustrated as electrode pins (116) in the examples mentioned above. It has been found that improvements to the electrode pins may be made. In particular, the electrode pins of the present disclosure may be configured to take on a particularly aerodynamic shape. For example, an article for use as part of a non-flammable aerosol delivery system is provided, the article comprises an aerosol generating component located at least partially within an aerosol generating chamber, wherein the article further comprises at least one electrode pin extending through the aerosol generating chamber to contact the aerosol generating component, wherein at least one region of the external profile of the electrode pin may be configured to increase the aerosol collected matter (ACM) generated by the article.

[0138] FIG. 11 illustrates an electrode pin (500) according to the present disclosure configured to take an aerodynamic shape. The following description will be understood to apply to one or both of the electrode pins in the article.

[0139] In particular, the electrode pin (500) includes a first end (501) and a second end (502). A connecting section (503) is connected between the first end and the second end. The first end (501) is configured to establish appropriate electrical contact with an aerosol generating component (e.g., the aerosol generating component (130) described above). Such contact can be created by pressing the first end (501) through the tab (131) of the aerosol generating component. In some embodiments, the first end (501) of the electrode pin (of any of the embodiments described herein) may include a collar (504). The collar is configured to interact with the tab (131) of the aerosol generating component (130) to improve the elasticity of the electrical contact between the pin and the aerosol generating component (130). The second end (502) of the electrode pin also includes two retaining collars (505a and 505b). These collars are spaced apart to create a receiving space for the wall of the second outer housing component (110b). Thus, when the electrode pins are inserted through a suitable hole in the second outer housing component (110b), the collars (505a and 505b) are positioned across the wall of the second outer housing component (110b) to hold the electrode pins in place. One or more sealing components may be provided at the interface between the collars (505a and 505b) and the second outer housing component (110b) to prevent or suppress the leakage of liquid from the aerosol generating chamber (148).

[0140] As described above, the electrode pins (500) include a connection zone (503). The connection zone (503) extends across the first end (501) and the second end (502) of the pin. When the pin is positioned in an aerosol generating chamber or any kind of airflow path, the aerosol collected matter (ACM) generated by the article can be increased compared to the ACM generated by the pin having a connection zone with a circular cross-section, due to the relatively aerodynamic profile of at least the connection zone. For example, by configuring at least the connection zone (503) of the pin to have a relatively increased aerodynamic profile, the airflow velocity within the aerosol generating chamber can be affected. Without being bound by theory, it is understood that by using a pin having at least a connection zone formed to have a relatively increased aerodynamic profile, the local velocity of the airflow upstream of the pin can be increased. This relatively increased velocity contributes to an increase in the ACM in the article.

[0141] In this regard, reference may be made to FIGS. 12a, 12b, and 13. FIG. 12a provides a representation of the airflow velocity around circular electrode pins located in an aerosol generation chamber. FIG. 12b provides a representation of the airflow velocity around aerodynamically configured electrode pins located in the corresponding aerosol generation chamber. Various shadings correspond to the airflow velocity within the aerosol generation chamber. As can be seen by comparing FIG. 12a and 12b, when the pins have a connecting zone of a circular cross-section, the regions of relatively lower velocity extend deeper into the central region of the aerosol generation chamber and further around the pins compared to when the pins have a more aerodynamic configuration. The effect of this on the ACM generated by each article is illustrated in FIG. 13. An article having the circular pin configuration of FIG. 12a has a lower ACM compared to an article having the aerodynamic pin configuration of FIG. 12b.

[0142] In the example of FIG. 11, the connecting section (503) has an ellipsoidal cross-section (when viewed along the longitudinal axis of the fin). Thanks to this cross-section, the airflow passing through the fin is less exposed to turbulence than when the fin has a circular cross-section, and the velocity of the airflow around the fin and upstream of the fin is generally less inhibited. Other suitable shapes may be used to minimize turbulence of the airflow passing through the electrode. For example, the connecting section (503) may have a non-circular cross-section such as an elliptical cross-section, an ellipsoidal cross-section, an aerofoil cross-section, a teardrop cross-section, or a polygonal cross-section when viewed along the longitudinal axis of the fin.

[0143] If the fin has a polygonal cross-section, such as a diamond or a rectangle (when viewed along the longitudinal axis of the fin), any corners may be rounded to facilitate the flow of air around or over the corresponding corners. For example, in the cross-section of the connecting zone, two parallel edges may be connected by two rounded edges.

[0144] To affect the ACM generated by the article, the electrode pins must be oriented within the article so that the aerosol passes through the pins. In one embodiment, at least one of the aerodynamically configured electrode pins is located within a portion of the airflow path downstream from the aerosol generation point. Typically, at least one of the aerodynamically configured electrode pins will be located within the aerosol generation chamber of the article.

[0145] In one embodiment, the article comprises two aerodynamically configured electrode pins. Each aerodynamically configured electrode pin may be located within an aerosol generation chamber. Alternatively, one may be located within the aerosol generation chamber and the other outside the aerosol generation chamber. Alternatively, both pins may be located outside the aerosol generation chamber but may be located along an airflow path from the aerosol generation chamber to one or more outlets of the article. As described above, the article does not need to include a single airflow path from the aerosol generation chamber to one or more outlets, and each electrode may be located in a separate airflow path.

[0146] Since aerodynamically designed fins generally do not have a circular cross-section, it is important to properly align the fins within the airflow section during manufacturing so that the most aerodynamically suitable profile aligns with the direction of airflow.

[0147] To support the correct positioning of the electrode pin, the pin may include one or more orientation features configured to fit with a corresponding alignment feature elsewhere on the article (e.g., on a flow controller). When the article is assembled, at least one orientation feature, such as a notch (506), interacts with the alignment feature to rotate the pin (500) to a final position, which is the most aerodynamically advantageous position. However, there are other cases where such orientation features on the pin may be advantageous even when the pin has a circular cross-sectional profile. For example, the second end (the corresponding end of the pin facing a device containing a power source) may be configured to form an electrode formed in a specific way. For example, the electrode pins of the device may have a specific shape that requires article pins of a corresponding shape to make electrical contact. Using article and device pins with connection surfaces having different orientations may introduce a security element into the system. For example, if the device pins and article pins are not properly aligned, current cannot be delivered to the aerosol generating component, and the system will be unable to operate. By ensuring a specific orientation of the article and device pins, it is possible to guarantee that only articles with the correct article pin orientation can be used. This can be useful in preventing the use of counterfeit articles with incorrect pin configurations.

[0148] In any of the above cases, it can be seen that the specific shape of the pin (whether an aerodynamically configured section or a contact section facing the device) must be considered in conjunction with the orientation of said shape. Therefore, it is important to ensure the correct orientation of one or more electrodes. Accordingly, in one embodiment, an electrode pin is provided that includes one or more orientation features that serve to orient the electrode pin to a specific rotational configuration when mated with one or more alignment features of a corresponding component. In one embodiment, at least one orientation feature is a notch or a rib. One or more notches or ribs may be configured to fit with a corresponding alignment feature on a heater support within the article, so that the orientation feature may be mated only to the alignment feature in a specific rotational configuration. One of the notches or ribs may exhibit a tapered profile that facilitates engagement with the alignment feature.

[0149] An aerosol delivery system is further provided comprising a device having a first pair of electrodes each having a connecting surface, and an article having a second pair of electrodes each having a connecting surface configured to match the corresponding connecting surface of the first pair of electrodes, wherein the cross-section of the connecting surface of at least one of the electrodes is different from the cross-section of another electrode among the electrodes.

[0150] The various embodiments described herein are presented solely for the purpose of assisting in understanding and teaching the claimed features. These embodiments are provided only as representative samples of the embodiments and are not complete and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and it should be understood that other embodiments may be utilized and modifications made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, be composed of, or constitute essentially of suitable combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Additionally, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

Claim 1 An article for use as part of a non-combustible aerosol delivery system, wherein the article comprises an aerosol generating component located at least partially within an aerosol generating chamber, and the article further comprises at least one electrode pin, wherein the at least one electrode pin comprises a first end, a second end, and at least one connecting section between the first end and the second end, and wherein the first end of the electrode pin comprises one or more orienting features configured to orient the electrode pin into a specific rotational configuration when aligned with one or more alignment features of a corresponding component. Claim 2 Article for use as part of a non-flammable aerosol providing system, wherein one or more orientation features are notches in claim 1. Claim 3 Article for use as part of a non-flammable aerosol providing system, wherein one or more orientation features are ribs. Claim 4 Article for use as part of a non-flammable aerosol providing system, wherein at least the connecting section is aerodynamically configured. Claim 5 Article for use as part of a non-flammable aerosol providing system, wherein at least one connecting section has an oval cross section, an ellipsoidal cross section, an aerofoil cross section, a teardrop cross section, or a polygonal cross section when viewed along the longitudinal axis of the pin. Claim 6 An article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 5, the first end is configured to establish electrical contact with an aerosol generating component. Claim 7 An article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 5, the first end of the electrode pin also comprises a collar. Claim 8 An article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 5, the second end comprises two retaining collars. Claim 9 Article for use as part of a non-flammable aerosol delivery system, wherein the two retaining collars are spaced apart so as to span the wall of an outer housing component through which the electrode pin protrudes. Claim 10 Article for use as part of a non-flammable aerosol delivery system, wherein, in claim 9, one or more sealing components are provided at the interface between the retaining collars and the external housing component. Claim 11 An article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 5, the second end comprises a connecting surface configured to match a corresponding connecting surface of a corresponding electrode. Claim 12 Article for use as part of a non-flammable aerosol providing system, wherein the connecting surface of the second end has a non-circular cross-section. Claim 13 A non-combustible aerosol providing system comprising an article of any one of claims 1 to 5, and a device comprising a power source and a control unit. Claim 14 A non-flammable aerosol providing system comprising a device having a first pair of electrodes each having a connecting surface, and an article having a second pair of electrodes each having a connecting surface configured to match the corresponding connecting surface of the first pair of electrodes, wherein the cross-section of the connecting surface of at least one of the electrodes is different from the cross-section of the connecting surface of another electrode among the electrodes. Claim 15 A non-flammable aerosol providing system comprising a device having a first pair of electrodes each having a connecting surface, and an article having a second pair of electrodes each having a connecting surface configured to align with a corresponding connecting surface of the first pair of electrodes, wherein the cross-section of the connecting surface of at least one of the electrodes is different from the cross-section of the connecting surface of another electrode among the electrodes, and at least one of the electrodes is an electrode pin comprising a first end, a second end, and at least one connecting section between the first end and the second end, and the first end of the electrode pin comprises one or more orienting features configured to orient the electrode pin in a specific rotational configuration when aligned with one or more alignment features of a corresponding component. Claim 16 delete

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