Provision system

Abstract

The present invention relates to an article for use as part of a non-flammable aerosol supply system, the article comprising a housing having a first section and a second section together forming a reservoir for an aerosolizable material — the first section and the second section are connected together to provide at least one pair of opposing surfaces —; a capillary channel is provided between the opposing surfaces, and at least one of the opposing surfaces comprises at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel.

Description

Technology Field

[0001] The present invention relates to a delivery system. In particular, the present invention relates to an article for use as part of a non-combustible aerosol delivery system, a non-combustible aerosol delivery system comprising the article, and a method for manufacturing the article. 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 spraying of the aerosolizable material. This spraying may be achieved mechanically, for example, by applying vibrations to the aerosolizable material to form small material particles mixed into the airflow. Alternatively, this spraying may 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] When an aerosol delivery system is used to simulate a smoking experience, such as with e-cigarettes or similar products, controlling these various characteristics is particularly important because the user can anticipate the specific sensory experience that will result from using the system.

[0005] It would be desirable to provide aerosol delivery systems having improved control of these characteristics.

[0006] According to a first aspect of the present disclosure, an article for use as part of a non-flammable aerosol providing system is provided, the article comprises a housing having a first section and a second section that together form a reservoir for an aerosolizable material — the first section and the second section are connected together to provide at least one pair of opposing surfaces —; a capillary channel is provided between the opposing surfaces, and at least one of the opposing surfaces comprises at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel.

[0007] One of the first and second sections may at least partially surround the other of the first and second sections.

[0008] One of the first section and the second section may at least partially surround the other of the first section and the second section to form a connection between the first section and the second section.

[0009] One of the first section and the second section may at least partially surround the other of the first section and the second section to provide at least one pair of opposing surfaces.

[0010] One of the first section and the second section may be inserted at least partially into the other of the first section and the second section.

[0011] One of the first section and the second section may include an insertion portion, and the other of the first section and the second section may include a receiving portion. The insertion portion may be inserted into the receiving portion.

[0012] At least one pair of opposing surfaces may be provided by the first section and the second section.

[0013] At least one pair of opposing surfaces may be provided by an insertion part and a receiving part.

[0014] The first section and the second section may be connected together by an interference fit, a press fit, a friction fit, and / or a transition fit.

[0015] The first section and the second section may be connected together to provide more than one pair of opposing surfaces (e.g., two, three, four, five, or six). For example, the first surface of the first section and the first surface of the second section may be opposing, and the second surface of the first section and the second surface of the second section may be opposing, thereby providing two pairs of opposing surfaces.

[0016] Each pair of opposing surfaces may have an opposing surface provided by a receiving portion, and the opposing surfaces of the same pair of opposing surfaces may have an inserting portion.

[0017] One, more than one, or each pair of opposing surfaces may extend independently substantially axially with respect to the axis of the housing. One, more than one, or each pair of opposing surfaces may extend independently substantially radially with respect to the axis of the housing. One, more than one, or each pair of opposing surfaces may extend independently substantially angularly with respect to the axis of the housing. For example, one pair of opposing surfaces may extend substantially axially with respect to the axis of the housing, and the other pair of opposing surfaces may extend substantially radially with respect to the axis of the housing.

[0018] The axis of the housing may correspond to an axis extending between the ends of the housing (e.g., the top and bottom). The axis of the housing may correspond to the longitudinal axis of the housing. The axis of the housing may correspond to an axis in which the first section and the second section are connected together.

[0019] Opposing surfaces may have substantially the same hardness. Opposing surfaces may have a Shore A hardness of 4 to 80.

[0020] Opposing surfaces can be manufactured from the same material.

[0021] Opposing surfaces can be manufactured from rigid materials.

[0022] Opposing surfaces can be manufactured from hydrophobic materials.

[0023] Non-limiting examples of materials suitable for use as opposing surfaces include plastics, glass, and metals. In some embodiments, the hydrophobic material is plastic. Non-limiting examples of suitable materials include nylon, polypropylene, silicone, or polycarbonate.

[0024] In the embodiments, at least one surface feature may be the only means for inhibiting or preventing capillary flow of an aerosolizable material through a capillary channel from a reservoir.

[0025] In the embodiments, the article may include a dedicated sealing element for inhibiting or preventing capillary flow of an aerosolizable material through a capillary channel from a reservoir. The dedicated sealing element may be a soft sealing element, such as an O-ring. The dedicated sealing element may be provided in the capillary channel. In the embodiments, the article may not include a dedicated sealing element.

[0026] At least one of the opposing surfaces may include more than one surface feature.

[0027] More than one opposing surface may include at least one surface feature.

[0028] More than one opposing surface may include more than one surface feature.

[0029] At least one surface feature can be continuously extended around its individual opposing surface such that an aerosolizable material cannot flow from a reservoir through a capillary channel without being blocked by at least one surface feature.

[0030] At least one surface feature may include at least one groove. At least one surface feature may be at least one groove. At least one surface feature may include a hydrophobic material, e.g., a hydrophobic coating.

[0031] At least one groove has width and depth.

[0032] At least one groove may have a width of at least 0.3 mm. At least one groove may have a width of up to 2.0 mm, or up to 1.0 mm, or up to 0.8 mm, or up to 0.6 mm.

[0033] At least one groove may have a depth of at least 0.3 mm. At least one groove may have a depth of up to 2.0 mm, or up to 1.0 mm, or up to 0.8 mm, or up to 0.6 mm.

[0034] At least one groove may be generally or substantially annular in shape.

[0035] At least one groove can be substantially straight when viewed from the side.

[0036] At least one groove can be substantially curved when viewed from the side.

[0037] At least one groove may be undulating when viewed from the side.

[0038] At least one groove can form a tortuous path when viewed from the side.

[0039] At least one groove can form a zigzag when viewed from the side.

[0040] If more than one groove exists, the grooves may be spaced apart from each other.

[0041] Where more than one surface feature exists, each surface feature may independently include any combination of features described herein, including any features as described herein.

[0042] According to a second aspect of the present disclosure, a non-combustible aerosol providing system is provided, wherein the non-combustible aerosol providing system comprises: an article for use as part of a non-combustible aerosol providing system according to a first aspect of the present disclosure; and a device comprising one or more of a power source and a controller.

[0043] According to a third aspect of the present disclosure, a method for manufacturing an article according to a first aspect of the present disclosure is provided, and the method is,

[0044] The step of providing a housing having a first section and a second section; and

[0045] The method comprises the step of connecting a first section and a second section together to form a reservoir for an aerosolizable material — the first section and the second section are connected to provide at least one pair of opposing surfaces —;

[0046] A capillary channel is provided between opposing surfaces, and at least one of the opposing surfaces includes at least one surface feature for inhibiting or preventing capillary flow of an aerosolizable material through the capillary channel from a reservoir.

[0047] 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 and can be combined with the specific combinations described above, as well as with embodiments of the invention according to other aspects of the invention. Brief explanation of the drawing

[0048] Various embodiments will now be described in detail merely as examples with reference to the attached drawings: FIG. 1 is a schematic representation of an aerosol providing device according to the present disclosure. FIG. 2 is a side cross-sectional view of an article to be used as part of a non-flammable aerosol providing system according to the present disclosure. Figure 3 is an enlarged side cross-sectional view of a part of the article of Figure 2. FIG. 4 is a perspective view of the first section of the article of FIG. 2. FIG. 5 is a side view of the second section of the article of FIG. 2. FIG. 6 is a side view of an exemplary second section of an article of the present disclosure. FIG. 7 is a side view of another exemplary second section of the article of the present disclosure. FIG. 8 is a side view of another exemplary second section of the article of the present disclosure. FIG. 9 is an enlarged side cross-sectional view of a part of the article of the present disclosure. FIG. 10 is an enlarged side cross-sectional view of an alternative article of the present disclosure. FIG. 11 is an enlarged side cross-sectional view of an alternative article of the present disclosure. FIG. 12 is an enlarged side cross-sectional view of an alternative article of the present disclosure. FIG. 13 is an enlarged side cross-sectional view of an alternative article of the present disclosure. FIG. 14 is an enlarged side cross-sectional view of an alternative article of the present disclosure. Specific details for implementing the invention

[0049] 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 orally and are not discussed or described in detail for the sake of brevity. Accordingly, it will be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented according to any prior art for implementing such aspects and features.

[0050] As described above, the present disclosure relates to non-combustible aerosol delivering systems and devices for generating aerosols from an aerosol generating material (which may also be referred to herein as an aerosolizable material) without burning the aerosol generating material (but is not limited thereto). Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (which generate aerosols using a combination of aerosol generating materials). In some examples, the non-combustible aerosol delivering 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 delivering system is an aerosol generating material heating system, also known as a heat-non-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.

[0051] Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may be used from time to time. However, it will be recognized that these terms may be used interchangeably with non-flammable aerosol (vapor) delivery systems or devices as described above.

[0052] 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.

[0053] A non-flammable aerosol delivery system typically comprises a device component (which may also be referred to herein as a device) and a consumable / article component (which may also be referred to herein as an article). The device component typically comprises a power source and a controller. The power source may typically be an electric power source, for example, a rechargeable battery.

[0054] 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.

[0055] 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 (which may also be referred to herein as a storage), an aerosol generating material transfer component, an aerosol generator (which may also be referred to herein as an aerosol generating component), an aerosol generating area (which may also be referred to herein as a chamber), a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0056] The systems described herein typically generate an inhalable aerosol by vaporizing an aerosol generating material. The aerosol generating material may comprise one or more active ingredients, one or more flavors, one or more aerosol forming (former) materials, and / or one or more other functional materials.

[0057] The aerosol-generating material may be in the form of a solid, liquid, or gel that may or may not contain active substances and / or flavoring agents, for example. 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 retaining 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.

[0058] 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, nutraceuticals, nootropics, and psychoactives. The active substance may occur naturally or be obtained by synthesis. 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 botanicals.

[0059] The aerosol forming agent material may include one or more components capable of forming an aerosol. In some examples, the aerosol former material may include 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.

[0060] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0061] As used herein, the term “component” is used to refer to a part, section, unit, module, assembly, or similar of a non-combustible aerosol delivery system, such as an electronic cigarette or similar device, comprising some smaller parts or elements, possibly within an exterior housing or wall. An electronic cigarette may be formed or made of one or more such components, and the components may be removable and 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.

[0062] FIG. 1 is a very schematic drawing (not actual scale) of an exemplary non-combustible aerosol / vapor delivery system such as an e-cigarette (10). The e-cigarette (10) has a generally cylindrical shape extending along a longitudinal axis indicated by a dotted line and comprises two main components: a control or power component or section (20) (which may also be referred to as a device), and a cartridge assembly or section (30) acting as a vapor generating component (which may also be referred to as an article, consumable, cartomizer, or cartridge).

[0063] The cartridge assembly (30) comprises a storage compartment (which may also be referred to herein as a storage unit) (3) that holds an aerosolizable material comprising a liquid formulation (e.g., one that generates an aerosol) containing nicotine. For example, the aerosolizable material may contain about 1 to 3 percent nicotine and 50 percent glycerol, with the remainder being approximately propylene glycol, and may also contain 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 include 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 within the storage compartment (3) to absorb an 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. Thus, this aerosolizable material is vaporized and replaced with a new aerosolizable material transferred to the vapor generating element (4) by the wick.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] The power component (20) includes a cell or battery (5) (which is also referred to herein 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.

[0069] 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, magnetic, 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 connected in other configurations such as a parallel arrangement. The system may or may not be largely cylindrical, and / or may or may not have a largely 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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, 70% or more. The open-pore fiber structure may be composed of, for example, a non-woven fabric that can be arbitrarily compressed, and additionally, may be sintered to improve cohesion. Open-pore sintered structures can be composed of granular, fibrous, or floccular sintered composites, for example, produced by a film casting process. Open-pore deposited structures can be produced, for example, by a CVD process, a PVD process, or by flame spraying. Open-pore foams are, in principle, commercially available and can also be obtained in thin and fine-pore designs.

[0074] 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, but not mandatory, for the individual layers to be connected to each other by heat treatment such as sintering or welding. 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 manufactured by folding a single layer. Instead of stainless steel, conductive alloys having a higher electrical resistivity than stainless steel, such as NiCr alloys and CrFeAl alloys ("Kantal"), may also 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 a plurality of individual fibers together. In this case, the aerosol-generating component may consist of sintered fibers, such as sintered metal fibers.

[0075] 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 evaporator 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.

[0076] As described above, the aerosol-generating component may be formed from a 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 may be arranged to provide a sheet with a diameter of 8 to 12 μm and a thickness of 0.16 mm, and may be spaced apart to produce a material density of 100 g / m² to 1500 g / m², for example 150 g / m² to 1000 g / m², 200 g / m² to 500 g / m², or 200 to 250 g / m², and a porosity of 84%. 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.

[0077] 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.

[0078] 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 evaporator 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.

[0079] 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.

[0080] 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.

[0081] FIGS. 2 to 5 illustrate exemplary articles (or consumables) (100) for use as part of a non-flammable aerosol providing system (10) according to the present disclosure.

[0082] The article (100) comprises a housing (101) having a first section (102) and a second section (103). The first section (102) and the second section (103) together form a reservoir (104) for an aerosolizable material (200). The first section (102) and the second section (103) are connected together to provide at least one pair of opposing surfaces (106, 108 and 107, 109). A capillary channel (110) is provided between at least one of the opposing surfaces (106, 108 and 107, 109). Typically, the capillary channel (110) is an artifact of the process for manufacturing the article (100). That is, due to manufacturing tolerances, a capillary channel (110) is provided between opposing surfaces (106, 108 and 107, 109). In use, the aerosolizable material (200) in the reservoir (104) may leak through the capillary channel (110), thereby drawing the material through the capillary channel (110) by capillary force. A person skilled in the art will recognize that the capillary channel is a channel through which liquid aerosolizable material can be drawn by the capillary force of the surfaces of the channel.

[0083] Capillary leakage is undesirable for a number of reasons. For example, leaked aerosolizable material (200) can cause inconvenience and / or unpleasantness, thereby negatively affecting the user experience. Additionally, leaked aerosolizable material (200) is wasted. Furthermore, leaked aerosolizable material (200) can affect the performance of the system (10) and / or cause the user to perceive the system (10) as defective.

[0084] In an article (100) of the present invention, at least one of the opposing surfaces (106 to 109) comprises at least one surface feature (111) for inhibiting or preventing capillary flow of an aerosolizable material (200) from a reservoir (104) through a capillary channel (110). The surface feature (111) blocks the capillary flow of the aerosolizable material (200) through the capillary channel (110), thereby inhibiting or preventing capillary leakage of the aerosolizable material (200) from the reservoir (104) through the capillary channel (110). The aerosolizable material (200) is partially or completely prevented from flowing from the reservoir (104) into the at least one surface feature (111).

[0085] In these specific embodiments, each surface feature (111) is a groove. The use of grooves has been found to be particularly effective in reducing or preventing leakage through the capillary channel. Without being bound by theory, it is believed that at least one groove provides additional separation between opposing surfaces, thereby preventing capillary force from being maintained and thus reducing or preventing aerosolizable material from being drawn through the channel. Furthermore, the capillary force of the opposing surfaces (106 to 109) is believed to retain the aerosolizable material (200) within the capillary channel (110) upstream of at least one groove (111) (as illustrated in FIG. 3).

[0086] Due to the sealing effect of at least one surface feature (111), a dedicated (e.g., separate and / or non-integrated) sealing element, such as an O-ring, may not be required to suppress or prevent capillary flow of the aerosolizable material (200) from the reservoir (104) through the capillary channel (110). Accordingly, the article (100) of the present invention may be manufactured without including such a dedicated sealing element. In fact, at least one surface feature (111) may be the only means to suppress or prevent capillary flow of the aerosolizable material from the reservoir (104) through the capillary channel (110). Accordingly, the article (100) of the present invention may be more cost-effective to manufacture than articles of the prior art because the material cost of providing a dedicated sealing element can be avoided. Furthermore, the article (100) of the present invention may be simpler to manufacture than articles of the prior art because the step of assembling a dedicated sealing element into the article can be avoided. Additionally, the article (100) of the present invention may be more reliable than articles of the prior art because the risk of degradation, malfunction, and / or defect of dedicated sealing elements can be avoided. These issues relate particularly to articles having soft sealing parts, such as O-rings, which may be manufactured with defects and may degrade over time due to exposure to certain chemicals and / or certain environmental conditions, for example. Additionally, it is possible to form individual parts of the housing from a similar material, without including dedicated sealing elements such as O-rings, while still suppressing or preventing leakage of aerosolizable material. This simplifies manufacturing.

[0087] In the embodiment of FIG. 2, the housing (101) is generally cylindrical in shape and has an upper end (opposite to the second section (103)) and a lower end (at the second section (103)). The housing (101) has a longitudinal axis extending between its upper end and lower end. However, it will be recognized by those skilled in the art that the housing (101) and its first and second sections (102, 103) may be provided in various different shapes. For example, the housing (101) may generally be rectangular, such as a rectangular prism shape. For example, the housing (101) may generally be plate-shaped. For example, the housing (101) may taper toward one end or both ends.

[0088] In the embodiment of FIG. 2, the first section (102) is generally cylindrical. The first section (102) has a receiving portion (112) in the form of an end that defines an opening to the space. The exact shape of the receiving portion (112) may be changed. The first section (102) also has a closed opposite end. The second section (103) is generally plate-shaped. The second section (103) has an insertion portion (113) that is inserted into the receiving portion (112). The second section (103) has an abutment portion (114) that extends radially from the insertion portion (113). The abutment portion (114) abuts the receiving portion (112). Thus, the storage (104) corresponds to the space enclosed by the first section (102) and the second section (103). As described above, the exact shape and arrangement of the first section (102) and the second section (103) may be changed. For example, in some embodiments, the abutting portion (114) is optional.

[0089] The first section (102) and the second section (103) may be connected to provide more than one pair of opposing surfaces (106, 108 and 107, 109) (e.g., two, three, four, five, or six). In the embodiment of FIG. 2, the first surface (106) of the first section (102) and the first surface (108) of the second section (103) are opposite, and the second surface (107) of the first section (102) and the second surface (109) of the second section (103) are opposite, thereby providing two pairs of opposing surfaces (106, 108 and 107, 109).

[0090] One or more of each pair of opposing surfaces (106, 108 and 107, 109) may be substantially axially extended, substantially radially extended, or substantially obliquely extended with respect to the axis of the housing (101). The axis of the housing (101) may be an axis extending between the ends of the housing (101) (i.e., the uppermost end and the lowermost end). The axis of the housing (101) may be the longitudinal axis of the housing (101). The axis of the housing (101) may be an axis to which the first section (102) and the second section (103) are connected together (as described below).

[0091] In the embodiment of FIG. 2, one pair of opposing surfaces (106, 108) extends substantially axially with respect to the longitudinal axis of the housing (101), and the other pair of opposing surfaces (107, 109) extends substantially radially with respect to the longitudinal axis of the housing. Thus, the axial opposing surfaces (106, 108) are substantially perpendicular to the radial opposing surfaces (107, 109). As described above, a capillary channel (110) is provided between the opposing surfaces (106, 108 and 107, 109).

[0092] Those skilled in the art will recognize that the capillary channel (110) is schematically illustrated in the drawings. For example, the way the first section (102) and the second section (103) are connected together is such that parts of the opposing surfaces (106 to 109) will be in contact with each other, while other parts of the opposing surfaces (106 to 109) are spaced apart to form the capillary channel (110). The exact shape of the capillary channel (110) may vary from article to article because manufactured articles are not at least partially identical due to manufacturing tolerances. Those skilled in the art will recognize that the opposing surfaces (106 to 109) may be provided in various different shapes that may vary depending on the shape of the first section (102) and the second section (103).

[0093] In the embodiment of FIG. 2, at least one of the opposing surfaces (106 to 109) includes one or more surface features (111) for inhibiting or preventing capillary flow of an aerosolizable material through a capillary channel from a reservoir. In some embodiments, one surface feature (111) (as shown in FIG. 7 and FIG. 8) may exist. In some embodiments, one or more opposing surfaces (106 to 109) include at least one surface feature (111) for inhibiting or preventing capillary flow of an aerosolizable material through a capillary channel from a reservoir (as shown in FIG. 12).

[0094] In the illustrated embodiments, each surface feature (111) is a groove (although it will be understood that other surface features are conceived). The groove(s) (111) may take on various different shapes and configurations. In the embodiment of FIG. 2, each groove (111) is substantially straight when viewed from the side (as shown in FIG. 5). In other embodiments, at least one groove (111) may be substantially curved when viewed from the side (as shown in FIG. 6). In other embodiments, at least one groove (111) may be undulating when viewed from the side (as shown in FIG. 7). In other embodiments, at least one groove (111) may form a serpentine path when viewed from the side (as shown in FIG. 8). For example, at least one groove (111) may form a zigzag when viewed from the side. The advantage of substantially curved (e.g., wavy or serpentine) or zigzag grooves is that they can cover a large surface area. By covering a large surface area, the risk of capillary leakage can be further reduced.

[0095] In the embodiment of FIG. 2, each groove (111) has a substantially polygonal cross-section taken perpendicular to the groove (111) (e.g., see FIG. 9). In other embodiments, at least one groove (111) may have a substantially curved or U-shaped cross-section taken perpendicular to the groove (111) (as shown in FIG. 10).

[0096] In the embodiment of FIG. 2, the (axial) opposing surface (108) of the second section (103) includes two grooves (111). In some embodiments, at least one opposing surface (106) of the first section (102) includes at least one groove (111) (as shown in FIG. 11).

[0097] Where more than one pair of opposing surfaces (106, 108 and 107, 109) exist, at least one of each pair of opposing surfaces may include at least one surface feature (111) (as illustrated in FIG. 13 and FIG. 14). In FIG. 13, the (axial) opposing surface (108) of the second section (103) includes at least one surface feature (111), and the (radial) opposing surface (109) of the second section (103) includes at least one surface feature (111). In FIG. 14, the (axial) opposing surface (106) of the first section (102) includes at least one surface feature (111), and the (radial) opposing surface (107) of the first section (102) includes at least one surface feature (111).

[0098] In the embodiment of FIG. 2, the surface features (111) are spaced apart from each other, and each surface feature (111) is substantially annular in shape. Each surface feature (111) extends continuously around its individual opposing surfaces (106 to 109) such that the aerosolizable material (200) cannot flow from the reservoir (104) through the capillary channel (110) without being blocked by at least one surface feature (111). This configuration is effective in preventing a capillary leak of the aerosolizable material from the reservoir. More specifically, each surface feature (111) extends continuously around the opposing (axial) surface (108) of the second section such that the aerosolizable material (200) cannot flow from the reservoir (104) through the capillary channel without being blocked by at least one surface feature (111).

[0099] In some embodiments, at least one surface feature (111) may partially extend around its individual opposing surfaces (106 to 109). Such embodiments may include a plurality of surface features (111). A plurality of surface features (111) together may provide effective sealing performance.

[0100] At least one groove (111) may have a depth of at least 0.3 mm. At least one groove (111) may have a width of at least 0.3 mm. These dimensions have been found to provide particularly effective sealing performance. At least one groove (111) may have a width of up to 2.0 mm, or up to 1.0 mm, or up to 0.8 mm, or up to 0.6 mm. At least one groove (111) may have a depth of up to 2.0 mm, or up to 1.0 mm, or up to 0.8 mm, or up to 0.6 mm.

[0101] Those skilled in the art will recognize that the groove(s) (111) may be provided in various shapes and dimensions. For example, the groove(s) (111) may generally be annular or not annular.

[0102] In the embodiments, one of the first section (102) and the second section (103) at least partially surrounds the other of the first section (102) and the second section (103) (e.g., see FIG. 2). For example, one of the first section (102) and the second section (103) may at least partially surround the other of the first section (102) and the second section (103) to form a connection between the first section (102) and the second section (103). For example, one of the first section (102) and the second section (103) may at least partially surround the other of the first section (102) and the second section (103) to provide at least one pair of opposing surfaces (106, 108). Accordingly, one of the first section (102) and the second section (103) may be inserted at least partially into the other of the first section (102) and the second section (103). It will be understood that other arrays are conceived.

[0103] The first section (102) and the second section (103) may be connected together by an engineering fit. For example, the first section (102) and the second section (103) may be connected together by an interference fit, a press fit, a friction fit, and / or a transition fit. These fits can provide a reliable connection and simplify the manufacture of the article (100).

[0104] In the embodiments, one of the first part (102) and the second part (103) at least partially surrounds the other part of the first part (102) and the second part (103) to form a connection between the first section (102) and the second section (103), and the connection is one or more of a press fit, a press fit, a friction fit, and / or a transition fit. Due to this arrangement, a simple and reliable connection can be formed between the first section (102) and the second section (103). Accordingly, separate fastening means (e.g., screws and pins) for connecting the first section (102) and the second section (103) together may not be required, and fewer components with a potential for failure may be required.

[0105] In the embodiment of FIG. 2, the receiving portion (112) surrounds the insert portion (113) to provide a press fit, press fit, friction fit, and / or transition fit between the first section (102) and the second section (103). Those skilled in the art will recognize a method of providing these types of engineered fits by sizing the first section (102) and the second section (103) accordingly. In some embodiments, the opposing surfaces (106 to 109) may have substantially the same hardness. The opposing surfaces (106 to 109) may have a Shore A hardness of 4 to 80 on the Shore A scale. In the context of the present invention, hardness is measured using Shore A hardness. This hardness has been found to result in surface features (111) that are particularly effective for sealing against capillary leakage.

[0106] The opposing surfaces (106 to 109) can be made of the same material. The advantage of this is that the manufacturing of the article can be simplified.

[0107] The opposing surfaces (106 to 109) can be made of a rigid material. This has been found to result in a rigid article that is particularly effective when sealing against capillary leakage.

[0108] The opposing surfaces (106 to 109) may be made of a hydrophobic material or treated with a hydrophobic material. The hydrophobic material may help inhibit or prevent the movement of aerosolizable material by capillary action, and thus help inhibit or prevent capillary leakage through the capillary channel.

[0109] Non-limiting examples of suitable materials for use as opposing surfaces (106 to 109) include plastics, glass, and metals. Non-limiting examples of suitable materials include nylon, polypropylene, silicone, or polycarbonate. The first section (102) may be formed of any of the materials disclosed herein. The second section (102) may be formed of any of the materials disclosed herein.

[0110] Now, the manufacture of the article (100) will be described as a non-limiting example. The first section (102) and the second section (103) of the housing (101) may be provided by any suitable technique such as injection molding. The first section (102) and the second section (103) are connected together to form a reservoir (104) for an aerosolizable material (200), and the first section (102) and the second section (103) are connected together to provide at least one pair of opposing surfaces (106, 108 and 107, 109). Due to the manufacturing tolerances of the first section (102) and the second section (103), a capillary channel (110) is provided between the opposing surfaces (106, 108 and 107, 109). At least one of the opposing surfaces (106 to 109) includes at least one surface feature (111) for inhibiting or preventing capillary flow of an aerosolizable material (200) through a capillary channel (110) from a reservoir (104).

[0111] To connect the first section (102) and the second section (103) together, the first section (102) and the second section (103) can be pushed together. This may result in at least a portion of one of the first section (102) and the second section (103) being inserted into the other of the first section (102) and the second section (103) (depending on the shape of the first section (102) and the second section (103), respectively). In other words, this may cause one of the first section (102) and the second section (103) to at least partially surround the other of the first section (102) and the second section (103).

[0112] In the embodiment of FIG. 2, the insert portion (113) is inserted into and through the opening (112) so that the abutting portion (114) abuts the end of the first portion (102) defining the opening (112). Due to the individual sizing of the first section (102) and the second section (103), the insertion results in a fixed connection between the first section (102) and the second section (103). The connection may be made through an engineering fit such as a press fit, a press fit, a friction fit, and / or a transition fit.

[0113] The aerosolizable material (200) may be deposited in the reservoir (104) before the first section (102) and the second section (103) are connected together. Alternatively, the aerosolizable material (200) may be deposited in the reservoir (104) after the first section (102) and the second section (103) are connected together, for example, by inserting the aerosolizable material (200) through an aperture (not shown) of the housing (101) which is subsequently sealed (e.g., by heat). Typically, the aerosolizable material (200) is a liquid (although gels may also be used).

[0114] In the illustrated embodiments, the surface features (111) are grooves, but it is conceived that other forms of surface features may be used. For example, the surface features may include a hydrophobic material (e.g., a hydrophobic coating).

[0115] The drawings presented herein are schematic and are not drawn to scale. The various embodiments described herein are presented merely to aid understanding and to teach the claimed features. These embodiments are provided only as representative samples of the embodiments and are not comprehensive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered as limitations on the scope of the invention as defined by the claims or limitations on equivalents thereof, and 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 other disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions that are not currently claimed but will be claimed in the future.

Claims

Claim 1 An article for use as part of a non-combustible aerosol provision system, wherein the article comprises a housing having a first section and a second section together forming a reservoir for an aerosolizable material — said first section and said second section are connected together to provide at least one pair of opposing surfaces —; a capillary channel is provided between said opposing surfaces, said at least one of said opposing surfaces comprises at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through said capillary channel, said at least one surface feature being at least one groove. Claim 2 Article for use as part of a non-flammable aerosol providing system, wherein one of the first section and the second section at least partially surrounds the other of the first section and the second section. Claim 3 Article for use as part of a non-flammable aerosol providing system, wherein the first section and the second section are joined together by a press fit, press fit, friction fit, and / or transition fit. Claim 4 An article for use as part of a non-flammable aerosol supply system, wherein, in any one of claims 1 to 3, it does not include a dedicated sealing element for inhibiting or preventing capillary flow of an aerosolizable material from the storage through the capillary channel. Claim 5 An article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 3, at least one of the opposing surfaces comprises one or more surface features for preventing capillary flow of an aerosolizable material from the reservoir through the capillary channel. Claim 6 An article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 3, the at least one surface feature extends continuously around its individual opposing surface such that the aerosolizable material cannot flow from the reservoir through the capillary channel without being blocked by the at least one surface feature. Claim 7 An article for use as part of a non-flammable aerosol providing system, wherein the at least one groove has a width of at least 0.3 mm in claim 1. Claim 8 An article for use as part of a non-flammable aerosol providing system, wherein, in claim 1 or 7, at least one groove has a depth of at least 0.3 mm. Claim 9 Article for use as part of a non-flammable aerosol delivery system, wherein, in claim 1 or 7, at least one groove is generally or substantially in an annular shape. Claim 10 Article for use as part of a non-flammable aerosol supply system, wherein, in claim 1 or 7, at least one groove is substantially straight when viewed from the side. Claim 11 Article for use as part of a non-flammable aerosol delivery system, wherein, in claim 1 or 7, at least one groove is substantially curved when viewed from the side. Claim 12 Article for use as part of a non-flammable aerosol providing system, wherein, in claim 1 or 7, at least one groove is substantially in an undulating form when viewed from the side. Claim 13 Article for use as part of a non-flammable aerosol delivery system, wherein, in claim 1 or 7, at least one groove forms a tortuous path when viewed from the side. Claim 14 Article for use as part of a non-flammable aerosol providing system, wherein, in claim 1 or 7, at least one groove forms a zigzag when viewed from the side. Claim 15 Article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 3, the opposing surfaces have substantially the same hardness. Claim 16 Article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 3, the opposing surfaces have a Shore A hardness of 4 to 80. Claim 17 Article for use as part of a non-flammable aerosol providing system, wherein, in any one of claims 1 to 3, the aerosolizable material is an aerosolizable liquid. Claim 18 A non-combustible aerosol providing system comprising: an article for use as part of a non-combustible aerosol providing system according to any one of claims 1 to 3; and a device comprising one or more of a power source and a controller. Claim 19 A method for manufacturing an article according to any one of claims 1 to 3, the method comprising: providing a housing having a first section and a second section; and connecting the first section and the second section together to form a reservoir for an aerosolizable material — the first section and the second section are connected together to provide at least one pair of opposing surfaces — wherein a capillary channel is provided between the opposing surfaces, and at least one of the opposing surfaces comprises at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel, and said at least one surface feature is at least one groove. Claim 20 delete

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