Aerosol generator

Abstract

According to an aspect, there is provided an article for an aerosol provision device comprising an aerosol generating material, a resistive heating layer comprising a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol. The aerosol generating material is on the resistive heating layer. The article comprises an exposed electrical contact region of a first type of electrical contact configured to electrically connect with an electrical connector of the aerosol provision device and an exposed electrical contact region of a second type of electrical contact configured to electrically connect with the electrical connector of the aerosol provision device. The resistive heating element is at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact. The article comprises an opening in the article defining an air inlet of a flow path along which aerosol is able to flow in the article. The exposed electrical contact regions are at least substantially free from overlap with the air passage through the article.

Description

[0001] AEROSOL GENERATOR

[0002] Technical Field

[0003] The present invention relates to an aerosol generator of an article for an aerosol provision device. The present invention also relates to an aerosol provision system, a method of forming an aerosol generator of an article for an aerosol provision device, and a blank for forming an aerosol generator of an article for an aerosol provision device.

[0004] Background Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combusting. Examples of such products are so-called “heat not burn” products or tobacco heating devices or products, which release compounds by heating, but not burning, material. The material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine.

[0005] Aerosol provision systems, which cover the aforementioned devices or products, are known. Common systems use heaters to create an aerosol from a suitable medium which is then inhaled by a user. Often the medium used needs to be replaced or changed to provide a different aerosol for inhalation. It is known to use resistive heating systems as heaters to create an aerosol from a suitable medium.

[0006] Summary

[0007] According to an aspect, there is provided an article for an aerosol provision device comprising an aerosol generating material, a resistive heating layer comprising a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol. The aerosol generating material is on the resistive heating layer. The article comprises an exposed electrical contact region of a first type of electrical contact configured to electrically connect with an electrical connector of the aerosol provision device and an exposed electrical contact region of a second type of electrical contact configured to electrically connect with the electrical connector of the aerosol provision device. The resistive heating element is at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact. The article comprises an opening in the article defining an air inlet of a flow path along which aerosol is able to flow in the article. The exposed electrical contact regions are at least substantially free from overlap with the air path through the article.

[0008] In an embodiment of the above, the aerosol generator comprises an aerosol generating layer comprising aerosol generating material. The aerosol generating layer may be on the resistive heating layer.

[0009] In an embodiment of the above, wherein the article comprises a support wherein the resistive heating layer is on the support.

[0010] In an embodiment of any of the above, the support comprises a support layer. In an embodiment of any of the above, the support is electrically insulative.

[0011] In an embodiment of any of the above, the support comprises at least one of paper and card.

[0012] In an embodiment of any of the above, the aerosol generating material is in direct contact with the resistive heating layer. In an embodiment of any of the above, the aerosol generating layer is in direct contact with the resistive heating layer.

[0013] In an embodiment of any of the above, the aerosol generating material is in indirect contact with the resistive heating layer. In an embodiment of any of the above, the aerosol generating layer is in indirect contact with the resistive heating layer.

[0014] In an embodiment of any of the above, the resistive heating layer and the support layer define a substrate.

[0015] In an embodiment of any of the above, the aerosol generator comprises a laminate comprising the resistive heating layer and the support layer.

[0016] In an embodiment of any of the above, the laminate comprises the aerosol generating material. In an embodiment of any of the above, the laminate comprises the aerosol generating layer.

[0017] In an embodiment of any of the above, the support layer comprises a card layer.

[0018] In an embodiment of any of the above, the article comprises a body defining at least a portion of the flow path, wherein the resistive heating layer is on the body.

[0019] In an embodiment of any of the above, the air inlet may be defined by the body. In an embodiment of any of the above, the air inlet is formed through the body.

[0020] In an embodiment of any of the above, the body defines a body wall and the air inlet is defined in the body wall.

[0021] In an embodiment of any of the above, at least one of the exposed electrical contact regions of the first type and the second type of electrical contact is supported by the body. In an embodiment of any of the above, each of the exposed electrical contact regions of the first type and the second type of electrical contact is supported by the body.

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

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

[0024] In an embodiment of any of the above, the body comprises a body layer. In an embodiment of any of the above, the body layer comprises part of a stack of body layers comprising the body.

[0025] In an embodiment of any of the above, the air inlet is defined by an area of reduced number of body layers.

[0026] In an embodiment of any of the above, the article comprises a mouth end and a distal end, wherein the air inlet is at the distal end.

[0027] In an embodiment of any of the above, the article comprises a mouth end and a distal end, wherein the air inlet is between the mouth end and the distal end.

[0028] In an embodiment of any of the above, the air inlet is formed through the resistive heating layer. In an embodiment of any of the above, the air inlet is defined in the support.

[0029] In an embodiment of any of the above, the article comprises a substrate comprising the support layer and the resistive heating layer.

[0030] In an embodiment of any of the above, the air inlet is formed through the substrate. In an embodiment of any of the above, the air inlet is defined through the aerosol generating material. In an embodiment of any of the above, the air inlet is defined through the aerosol generating layer.

[0031] In an embodiment of any of the above, the air inlet is positioned upstream of each of the exposed electrical contact regions of the first type and the second type of electrical contact.

[0032] In an embodiment of any of the above, the air inlet is positioned downstream of each of the exposed electrical contact regions of the first type and the second type of electrical contact.

[0033] In an embodiment of any of the above, the air inlet is a first air inlet and the article comprises a second air inlet. In an embodiment of any of the above, the article comprises a wrap configured to wrap around at least a portion of the article, wherein the air inlet is formed in the wrap and the at least one of the exposed electrical contact regions of the first type and the second type of electrical contact is free from overlap with the wrap. In an embodiment of any of the above, the air inlet is on the same side of the article as the at least one of the exposed electrical contact regions of the first type and the second type of electrical contact.

[0034] In an embodiment of any of the above, the air inlet is on a different side of the article as the at least one of the exposed electrical contact regions of the first type and the second type of electrical contact.

[0035] In an embodiment of any of the above, the aerosol generating layer is a first aerosol generating layer and the article comprises a second aerosol generating layer comprising aerosol generating material.

[0036] In an embodiment of any of the above, the second aerosol generating layer is on the resistive heating layer.

[0037] In an embodiment of any of the above, the resistive heating layer is a first resistive heating layer and the article comprises a second resistive heating layer.

[0038] In an embodiment of any of the above, at least a portion of the second resistive heating layer forms a second resistive heating element, the second resistive heating element providing an electrically conductive path for resistive heating of at least a portion of the second aerosol generating material to generate an aerosol.

[0039] In an embodiment of any of the above, the body defines a space between the first aerosol generating layer and the second aerosol generating layer.

[0040] In an embodiment of any of the above, the space defines at least part of the flow path.

[0041] In an embodiment of any of the above, the cross section of the air inlet is one of square, rectangular, circular, oval, cruciform and pill-shaped.

[0042] In an embodiment of any of the above, the air inlet comprise a grating.

[0043] In an embodiment of any of the above, an exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and the width, wherein the length is greater than or equal to the width, and wherein the width is greater than the depth.

[0044] According to an aspect, there is provided an article for an aerosol provision device comprising an aerosol generating material and a resistive heating layer. The aerosol generating material is on the resistive heating layer. At least a portion of the resistive heating layer forms a resistive heating element configured to heat at least a portion of said aerosol generating material to generate an aerosol. The article comprises a first type of electrical contact and a second type of electrical contact, wherein the resistive heating element is at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact. The article comprises a body at least partially defining a flow path along which aerosol can flow in the article, wherein at least one of the first type of electrical contact and the second type of electrical contact is offset from the body.

[0045] In an embodiment of the above, the aerosol generator comprises an aerosol generating layer comprising aerosol generating material. The aerosol generating layer may be on the resistive heating layer.

[0046] In an embodiment of the above, the resistive heating layer forms the first type of electrical contact and the second type of electrical contact.

[0047] In an embodiment of the above, the resistive heating layer protrudes from the body. In an embodiment of the above, at least one of the first type of electrical contact and the second type of electrical contact protrudes from the body.

[0048] In an embodiment of any of the above, the aerosol generator comprises a support configured to support the resistive heating layer.

[0049] In an embodiment of any of the above, the support comprises a support layer. In an embodiment of any of the above, the support is electrically insulative.

[0050] In an embodiment of any of the above, the support comprises at least one of paper and card.

[0051] In an embodiment of any of the above, the aerosol generating material is in direct contact with the resistive heating layer. In an embodiment of any of the above, the aerosol generating layer is in direct contact with the resistive heating layer.

[0052] In an embodiment of any of the above, the aerosol generating material is in indirect contact with the resistive heating layer. In an embodiment of any of the above, the aerosol generating layer is in indirect contact with the resistive heating layer.

[0053] In an embodiment of any of the above, the resistive heating layer and the support layer define a substrate.

[0054] In an embodiment of any of the above, the aerosol generator comprises a laminate comprising the resistive heating layer and the support layer.

[0055] In an embodiment of any of the above, the laminate comprises the aerosol generating material. In an embodiment of any of the above, the laminate comprises the aerosol generating layer.

[0056] In an embodiment of any of the above, the support layer comprises a card layer. In an embodiment of any of the above, the article comprises a protruding panel protruding from the body, wherein at least one of the first type of electrical contact and the second type of electrical contact is on the protruding panel.

[0057] In an embodiment of any of the above, the protruding panel comprises the support.

[0058] In an embodiment of any of the above, the protruding panel comprises the resistive heating layer.

[0059] In an embodiment of any of the above, the protruding panel protrudes from a longitudinal end of the body. In an embodiment of any of the above, the protruding panel protrudes from a longitudinal side of the body.

[0060] In an embodiment of any of the above, the substrate extends from the body.

[0061] In an embodiment of any of the above, the substrate defines the protruding panel.

[0062] In an embodiment of any of the above, the article comprises an opening in the body defining an air inlet of the flow path.

[0063] In an embodiment of any of the above, at least one of the first type of electrical contact and the second type of electrical contact is free from overlap with the flow path.

[0064] In an embodiment of any of the above, the first type of electrical contact is configured to electrically connect with a device electrical connector and the second type of electrical contact is configured to electrically connect with the device electrical connector.

[0065] In an embodiment of any of the above, the support defines an exposed contact area of the first type of electrical contact.

[0066] In an embodiment of any of the above, wherein the exposed contact area is a first exposed contact area, and the support defines a second exposed contact area of the second type of electrical contact.

[0067] In an embodiment of any of the above, the aerosol generating material is a continuous aerosol generating material. In an embodiment of any of the above, the aerosol generating layer is a continuous aerosol generating layer. In an embodiment of any of the above, the aerosol generating material is a discontinuous aerosol generating material. In an embodiment of any of the above, the aerosol generating layer is a discontinuous aerosol generating layer.

[0068] In an embodiment of any of the above, the aerosol generating material comprises a plurality of discrete aerosol generating portions. In an embodiment of any of the above, the aerosol generating layer comprises a plurality of discrete aerosol generating portions. In an embodiment of any of the above, the resistive heating element is one of a plurality of resistive heating elements.

[0069] In an embodiment of any of the above, one of the discrete aerosol generating portions is associated with a corresponding one of the plurality of resistive heating elements.

[0070] In an embodiment of any of the above, the aerosol generating layer comprises at least one of dots, strips and patches.

[0071] In an embodiment of any of the above, wherein the resistive heating element is a first heating element and the resistive heating layer forms a second resistive heating element, each resistive heating element providing an electrically conductive path for resistive heating of a portion of the aerosol generating material to generate an aerosol at the respective portion of the aerosol generating material.

[0072] In an embodiment of any of the above, wherein the resistive heating element is a first heating element and the resistive heating layer forms a second resistive heating element, each resistive heating element providing an electrically conductive path for resistive heating of a portion of the aerosol generating material to generate an aerosol at the respective portion of the aerosol generating layer.

[0073] In an embodiment of any of the above, wherein the resistive heating layer forms an array of resistive heating elements comprising at least the first resistive heating element and the second resistive heating element.

[0074] In an embodiment of any of the above, wherein each of the first type of electrical contact and the second type of electrical contact are configured to enable an electric current to be individually provided to each of the resistive heating elements.

[0075] In an embodiment of any of the above, wherein the aerosol generating layer comprises a film or gel layer comprising the aerosol generating material.

[0076] In an embodiment of any of the above, the aerosol generator comprises a plurality of the first type of electrical contact, wherein each of the heating elements comprises a separate electrical contact of the first type.

[0077] In an embodiment of any of the above, the aerosol generator comprises a plurality of the second type of electrical contacts, wherein each of the resistive heating elements comprises a separate second type of electrical contact.

[0078] In an embodiment of any of the above, wherein the aerosol generator comprises a single second type of electrical contact.

[0079] In an embodiment of any of the above, wherein the single second type of electrical contact is shared between each of the resistive heating elements. In an embodiment of any of the above, the resistive heating element is formed by at least one of: cutting said resistive heating layer; chemically etching said resistive heating layer; forming or pressing the resistive heating layer in the substrate; and printing said resistive heating layer. In an embodiment of any of the above, the resistive heating layer is in the form of a foil.

[0080] According to an aspect, there is provided an aerosol provision system comprising an article according to any of the above embodiments and an aerosol provision device configured to receive at least a portion of the article. In an embodiment of any of the above, the aerosol provision device comprises an electrical connector configured to electrically connect with the first type of electrical contact and the second type of electrical contact.

[0081] In an embodiment of any of the above, the electrical connector comprises device electrical contacts. In an embodiment of any of the above, in use, the device electrical contacts are free from overlap with the flow path.

[0082] In an embodiment of any of the above, in use, the device electrical contacts overlay the body.

[0083] In an embodiment of any of the above, in use, the device electrical contacts act against the body.

[0084] In an embodiment of any of the above, in use, the device electrical contacts act on a portion of the resistive heating layer overlapping the body.

[0085] In an embodiment of any of the above, in use, the flow path is substantially free from overlap with the electrical connector. In an embodiment of any of the above, in use, the electrical connector does not apply a force to the article directed substantially towards the flow path.

[0086] According to an aspect, there is provided an aerosol provision device comprising a body, a receptacle in the body defining a chamber configured to receive at least a portion of an aerosol generating article, a conduit in the body along which air can flow comprising an air outlet communicating with the chamber, and a sealing member in the receptacle defining at least a portion of the conduit configured to sealably engage with an aerosol generating article in the chamber. a sealing member in the receptacle defining at least a portion of the conduit configured to sealably engage with an aerosol generating article in the chamber. In an embodiment of any of the above, the sealing member is configured to define the air outlet. In an embodiment of any of the above, the sealing member is configured to align with an article air inlet of the article.

[0087] In an embodiment of any of the above, the sealing member is configured to seal over the article air inlet of the article. In an embodiment of any of the above, the sealing member is resilient.

[0088] In an embodiment of any of the above, the sealing member protrudes from the receptacle.

[0089] In an embodiment of any of the above, the sealing member is configured to bias the article to locate the article in the receptacle. In an embodiment of any of the above, the conduit is a first conduit and the device comprises a second conduit through which air can flow in the body, the second conduit comprising a second air outlet communicating with the chamber.

[0090] In an embodiment of any of the above, the sealing member is a first sealing member and the device comprises a second sealing member in the receptacle defining at least a portion of the second conduit and configured to sealably engage with the aerosol generating article in the chamber.

[0091] In an embodiment of any of the above, the second sealing member is configured to form the second air outlet.

[0092] In an embodiment of any of the above, the second sealing member is configured to align with a second article air inlet on the article.

[0093] In an embodiment of any of the above, the second sealing member is configured to seal over the second article air inlet on the article.

[0094] In an embodiment of any of the above, the first sealing member opposes the second sealing member. In an embodiment of any of the above, the first and second sealing members are configured to grip a portion of the article therebetween.

[0095] In an embodiment of any of the above, when the article is received by the device, the air outlet is configured to form a closed air pathway between the conduit and the article air inlet such that, in use, the article air inlet receives substantially only air from the air outlet.

[0096] In an embodiment of any of the above, the device comprises an electrical connector configured to electrically connect with the exposed electrical contact region of a first type of the article.

[0097] In an embodiment of any of the above, the electrical connector is configured to electrically connect with the exposed electrical contact region of a second type of the article. In an embodiment of any of the above, an exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and the width, wherein the length is greater than or equal to the width, and wherein the width is greater than the depth. In an embodiment of any of the above, the article defines a least one major face, and the air inlet is defined in the major face.

[0098] In an embodiment of any of the above, the aerosol provision device comprises a sensor configured to determine a change in air flow in the conduit.

[0099] In an embodiment of any of the above, the sensor is a microphone. In an embodiment of any of the above, the sensor is a puff detector.

[0100] According to an aspect, there is provided an aerosol generator of an article for an aerosol provision device comprising: aerosol generating material; a resistive heating layer comprising a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; a first type of electrical contact; and a second type of electrical contact; and wherein the resistive heating element is at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact.

[0101] The aerosol generator may comprise an aerosol generating layer comprising aerosol generating material. The aerosol generating layer may be on the resistive heating layer.

[0102] According to an aspect, there is provided an aerosol provision device configured to receive an aerosol generator or an article for an aerosol provision device of any of the above.

[0103] According to an aspect there is provided an aerosol provision system comprising an article comprising aerosol generating material and the aerosol provision device of according to any of the above embodiments.

[0104] Brief Description of the Drawings

[0105] Various embodiments will now be described, by way of example only, with reference to the accompanying schematic drawings, in which: Figure 1 is a schematic perspective view of an aerosol provision system;

[0106] Figure 2 is a schematic perspective view of an article comprising aerosol generating material of the aerosol provision system of Figure 1;

[0107] Figure 3 is a schematic perspective view of a first side of an aerosol generator of the article of Figure 2; Figure 4 is a schematic perspective view of part of a second side of the aerosol generator of Figure 3;

[0108] Figure 5 is a schematic block diagram of an aerosol provision system such as the system shown in Figure 1; Figure 6 is a schematic partially exploded perspective view of the article of Figure

[0109] 2, with an aerosol generator shown inverted from an assembled orientation and in a spaced relationship with other components;

[0110] Figure 7 is a schematic cross-sectional view of another aerosol generator such as the aerosol generator shown in Figure 3; Figure 8 is a schematic plan view of a heating element of the aerosol generator of

[0111] Figure 3;

[0112] Figure 9 is a schematic plan view of a resistive heating layer of the aerosol generator of Figure 3 with a plurality of heating elements;

[0113] Figure 10 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3;

[0114] Figure 11 is an exploded perspective view of an aerosol generator being formed;

[0115] Figure 12 is a schematic perspective view of a resistive heating layer of an aerosol generator being formed;

[0116] Figure 13 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3;

[0117] Figure 14 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3;

[0118] Figure 15 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3; Figure 16 is a schematic perspective view of a resistive heating layer of an aerosol generator being formed;

[0119] Figure 17 is a schematic plan view of a heating element of an aerosol generator;

[0120] Figure 18 is a schematic plan view of a heating element of an aerosol generator;

[0121] Figure 19 is a schematic perspective view of part of an aerosol generator of the article of Figure 2;

[0122] Figure 20 is a schematic perspective view of a device connector of an aerosol provision device of the aerosol provision system of Figure 1 ;

[0123] Figure 21 is a schematic side view of the aerosol generating system of Figure 1 ;

[0124] Figure 22 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3;

[0125] Figures 23 to 25 show an aerosol generator being formed; Figure 26 is a schematic cross-sectional plan view of the article of Figure 2;

[0126] Figure 27 is a schematic cross-sectional plan view of another article;

[0127] Figure 28 is a schematic cross-sectional plan view of another article;

[0128] Figure 29 is a schematic cross-sectional plan view of another article; Figure 30 is a schematic perspective view of the article of Figure 29.

[0129] Figure 31 is a schematic cross-sectional side view of another article provision system, including the article of Figure 29; and

[0130] Figure 32 is a schematic cross-sectional side view of another article provision system.

[0131] Detailed Description

[0132] As used herein, the term “delivery mechanism” is intended to encompass systems that deliver a substance to a user, and includes: non-combustible aerosol provision systems that release compounds from an aerosolisable material without combusting the aerosolisable material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosolisable materials; and articles comprising aerosolisable material and configured to be used in one of these non-combustible aerosol provision systems.

[0133] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

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

[0135] In some embodiments, the non-combustible aerosol provision 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.

[0136] In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

[0137] Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.

[0138] In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

[0139] In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source.

[0140] In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent.

[0141] In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0142] As used herein, the term “aerosol-generating material” (which is sometimes referred to herein as an aerosolisable material) is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol- generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and / or flavourants.

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

[0144] The aerosol-generating material may comprise one or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

[0145] The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and / or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

[0146] The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and / or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

[0147] The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

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

[0149] The aerosol-generating film may be discontinuous. For example, the aerosol- generating film may comprise one or more discrete portions or regions of aerosolgenerating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar.

[0150] In embodiments, the aerosol-generating material comprises a plurality of aerosolgenerating films. In embodiments, the aerosol-generating film comprises a plurality of aerosol-generating film regions. Such plurality of aerosol-generating films and / or plurality of aerosol-generating film regions may have different properties, for example at least one of different compositions, thicknesses, density, active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

[0151] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosol-generating film.

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

[0153] The aerosol-generating material may be an “amorphous solid”. In some embodiments, the amorphous solid is a “monolithic solid”. The aerosol-generating material may be non-fibrous or fibrous. In some embodiments, the aerosol-generating material may be a dried gel. The aerosol-generating material may be a solid material that may retain some fluid, such as liquid, within it. In some embodiments the retained fluid may be water (such as water absorbed from the surroundings of the aerosol- generating material) or the retained fluid may be solvent (such as when the aerosolgenerating material is formed from a slurry). In some embodiments, the solvent may be water.

[0154] The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0155] The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0156] The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy.

[0157] An aerosol provision device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into or onto the aerosol provision device before it is heated to produce an aerosol, which the user subsequently inhales.

[0158] An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol.

[0159] A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosolgenerating material storage area, an aerosol-generating material transfer component, an aerosol transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol- generating material to generate aerosol in use. The heater may comprise a conductor which can be heated by the passage of an electrical current through the conductor.

[0160] Non-combustible aerosol provision systems may comprise a modular assembly including both a reusable aerosol provision device and a replaceable aerosol generating article. In some implementations, the non-combustible aerosol provision device may comprise a power source and a controller (or control circuitry). The power source may, for example, comprise an electric power source, such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol provision device may also comprise an aerosol generating component. However, in other implementations the aerosol generating article may comprise partially, or entirely, the aerosol generating component.

[0161] Figure 1 shows a schematic view of an aerosol provision system 100. The aerosol provision system 100 comprises an aerosol provision device 200 and an article 300 comprising aerosol generating material 302 (refer to Figure 3). The article 300 is shown in Figure 2 removed from the aerosol provision device 200. An aerosol generator 304 of the article 300 is shown in Figure 3 with a perspective view of a first side 306, with a perspective view of part of a second side 307 shown in Figure 4.

[0162] The article 300 comprises the aerosol generator 304. The aerosol generator 304 is configured to generate an aerosol from the aerosol generating material 302 upon operation of the aerosol provision system 100, as will be described in detail below.

[0163] The aerosol provision system 100 may be elongate, extending along a longitudinal axis. The aerosol provision system 100 has a proximal end 102, which will be closest to the user (e.g. the user’s mouth) when in use by the user to inhale the aerosol generated by the aerosol provision system 100, and a distal end 104 which will be furthest from the user when in use.

[0164] The proximal end may also be referred to as the “mouth end”. The aerosol provision system 100 accordingly defines a proximal direction, which is directed towards the user when in use. Further, the aerosol provision system 100 likewise defines a distal direction, which is directed away from the user when in use. The terms ‘proximal’ and ‘distal’ as applied to features of the system 100 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along a longitudinal axis.

[0165] The article 300 is received by the aerosol provision device 200. The configuration of the article 300 and the aerosol provision device 200 may vary. In the present embodiment, the aerosol provision device 200 comprises a device body 202. The device has a housing 204 enclosing components of the device 200. An article receiving portion 206, sometimes referred to as a device chamber, as shown in Figure 5, is configured to receive a portion of the article 300. A proximal end 308 of the article protrudes from the device 200 when the article 300 is received in the device chamber 206. A receptacle 208 defines the chamber 206. The receptacle 208 comprises a receptacle base 210 and a receptacle peripheral wall 212. The configuration of the receptacle 208 may vary in dependence on the configuration of the article 300.

[0166] One or more user-operable control elements 224, such as a button or switch, which can be used to operate the aerosol provision system 100 may be provided on the aerosol provision device 200. For example, a user may activate the system 100 by pressing the control element 224. The one or more user-operable control elements may be omitted. In embodiments, the aerosol provision system 100 is operated by another user action, for example puff activated by a user drawing air through the system.

[0167] The aerosol provision device 200 comprises an opening 214 at the proximal end, leading into the device chamber 206. The opening 214 is provided in one end, through which the article 300 can be inserted. In embodiments, the article 300 may be fully or partially inserted into the device 200. The configuration of the device 200 may vary, for example the opening may be in a longitudinal side wall of the device 200, and / or may be closed by another feature of the device 200 during use. In the present configuration, the article 300 defines a mouthpiece 310 at the proximal end 308. In other embodiments, the device 200 defines the mouthpiece. The user places their mouth over the mouthpiece during use.

[0168] The device 200 defines the longitudinal axis along which an article 300 may extend when inserted into the device 200. The opening 214 is aligned on the longitudinal axis. The longitudinal axis may be an axis along which the article 300 is inserted into the device 200. The longitudinal axis may be considered to be a receiving axis of the device 200. The article 300 may similarly have a longitudinal axis along which it is inserted into the device and this axis may be considered to be an insertion axis.

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

[0170] As discussed in detail below, a heating system 110 is configured to heat the aerosol generating material 302 of an article 300. The article 300 in embodiments is a consumable, and is interchangeable with other articles 300. The heating system 110 comprises the aerosol generator 304. The heating system 110 comprises other components of the aerosol provision system 100 including components of the article 300 and the aerosol provision device 200, for example the power source 220 and the control circuit 222.

[0171] The aerosol generator 304 forms part of the article 300. The aerosol generator 304 comprises a heating arrangement 312 configured to heat aerosol generating material 302, for example at least one of a film and a gel to generate an aerosol. The aerosol generating material may be referred to as aerosolisable material.

[0172] The heating arrangement 312 is a resistive heating arrangement. The or each heating element in embodiments is a resistive heating element, as described in detail below. In such arrangements the heating system 110 comprises a resistive heating generator including components to heat the heating arrangement 312 via a resistive heating process. In this case, an electrical current is directly applied to a resistive heating element, and the resulting flow of current in the heating element, acting as a heating component, causes the heating element to be heated by Joule heating. The resistive heating element comprises resistive material configured to generate heat when a suitable electrical current passes through it, and the heating arrangement 312 comprises electrical contacts for supplying electrical current to the resistive material. The provision of a resistive heating arrangement 312 allows for a compact arrangement. Resistive heating provides an efficient configuration.

[0173] In the use of the aerosol provision system 100, air is drawn into an air inlet 314 of the article 300, as indicated schematically by arrow 316. As shown in Figure 2, the air inlet 314 is located on a side wall of the article 300. The air inlet 314 is between the mouth end and the distal end of the article 300. The air inlet is located proximal to the distal end of the article 300. In embodiments, the air inlet 314 may have a different configuration, for example at the distal end. The air inlet 314 is shown with a rectangular cross-section. In embodiments, the air inlet 314 may have any shaped cross-section. For example, square, circular, oval, cruciform, pill-shaped or any other suitable shape. The air flow to the air inlet 314 of the article 300 may be defined, for example by at least one of an air path through the device 200, an air path external to the device 200, and an air path between the device 200 and the article 300. An aerosol generated by the aerosol generator 304 exits the device at an aerosol outlet 318, as indicated by arrow 319. In embodiments the aerosol outlet 318 is in the mouthpiece of the article 300, such that the aerosol is drawn directly from the article 300 into the mouth of a user of the device 100. In some embodiments the air outlet 318 may be located at or toward the mouth end. The flow path of the article 300 is further detailed later. In some example embodiments, the aerosol provision system comprises two main components, namely a control section forming a reusable part and a consumable section forming a replaceable or disposable part which may be referred to as a replaceable or disposable article or cartridge. As described herein, the aerosol provision device 200 forms a control section and the article 300 forms the consumable section. In the use of the aerosol generating system, the control section and the consumable part may be releasably connected at an interface. The consumable part may be removable and replaceable, for example when the consumable part is used, with the control section being re-used with a different consumable part.

[0174] The aerosol provision system 100 as shown is provided by way of example only and is highly schematic. Different aerosol generating devices and other devices may be used in example implementations of the principles described here. For example, in some example embodiments, air is drawn into an air inlet in the control section, passes through the interface, and exits the consumable part.

[0175] As shown schematically in Figure 5, and described in detail below, the article 300 has an article electrical contact configuration 320. The electrical contact configuration 320 in embodiments is formed by the aerosol generator 304. The electrical contact configuration 320 comprises heater electrical contacts 322. The heater electrical contacts 322 may also be known as heater or article contacts. The aerosol provision device 200 comprises an electrical connector 230. The electrical connector 230 comprises connector electrical contacts 232. The connector electrical contacts 232 may also be known as connector or device contacts. The article electrical contact configuration 320 is configured to electrically communicate with the device electrical connector 230.

[0176] The configuration of the article 300 may vary. The article 300 comprises a body 324. The body 324 is hollow. The body 324 defines a flow path 326 (refer to Figures 6 and 26 to 32, for example) through the article 300. The flow path 326 extends between the air inlet 314 and the aerosol outlet 318. The flow path 326 is defined by an internal space in the article along which air and / or aerosol can flow. The flow path 326 is defined in the body 324. The body 324 may define any suitable shaped flow path 326. For example, the flow path 326 may be at least one of convoluted, angled, and tapered. The or each aerosol generator 304 bounds the flow path 326. The aerosol generating material 302 is exposed to the flow path 326. The aerosol generating material 302 is exposed in the internal space. The internal space in embodiments comprises two or more chambers.

[0177] The air inlet 314 comprises an opening 315. The opening 315 is formed in the body 324. The opening 315 is formed in a longitudinal wall of the body 324. The opening is spaced from the distal end of the body 324. In embodiments, the opening is formed in another component of the article 300, for example the aerosol generator 304 or another wall feature. The aerosol outlet 318 comprises an outlet opening 317. The outlet opening 317 is formed in the body 324. In embodiments, the outlet opening 317 is formed in another component of the article 300, for example the aerosol generator 304 or another wall feature. As shown in Figure 6, the article 300 comprises two aerosol generators 304 forming an aerosol generator arrangement. The number of aerosol generators 304 may differ. Each aerosol generator 304 comprises aerosol generating material 302. The aerosol generating material 302 is exposed to the flow path 326. In embodiments the article 300 comprises a single aerosol generator 304. One of the aerosol generators 304 will be described in detail, with such detail being applicable to one or more further aerosol generators 304 in embodiments.

[0178] The or each aerosol generator 304 and the body 324 are formed in a stacked configuration. In embodiments, other arrangements such as a tubular arrangement of the article are envisaged. In such tubular arrangements the aerosol generator 304 defines a tubular configuration. Tubular may include circular cross-sectional, an elliptical cross section and other polygonal shapes.

[0179] In embodiments, as shown in the Figures, the article 300 has a flat configuration. That is, wherein an exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and the width, wherein the length is greater than or equal to the width, and wherein the width is greater than the depth. Other configurations are envisaged.

[0180] Figure 6 is a partially exploded perspective view of the article 300, with an aerosol generator 304 shown inverted from an assembled orientation and in a spaced relationship with other components. The article 300 comprises a first one of the aerosol generator 302, the body 324 and a second one of the aerosol generator. The body 324 spaces the first and second aerosol generators 304. The first and second aerosol generators 304 close the internal space defined by the body 324 along which air and / or aerosol can flow. The aerosol generating material 302 of the first and second aerosol generators 304 face each other and is exposed to the internal space. When assembled, the first and second aerosol generators 304 sandwich the body 324. In the embodiment of Figure 6 at least, the first and second aerosol generators 304 and the body have equal plan areas. In embodiments, one or more of the first and second aerosol generators 304 and the body 324 has a greater length and / or width. In embodiments, one of the first and second aerosol generators 304 is replaced by a blank panel. The body 324 comprises a body layer. The body may comprise a plurality of body layers. The body layers may be formed in a stack and arranged to define features of the article 300, such as the air inlet 314 and aerosol outlet 318.

[0181] A wrap encircles the article 300 and forms part of the article 300. The wrap may comprise a sheet. The wrap acts as a fixed sleeve. The or each aerosol generator 304 protrudes from the wrap at a distal end. Exposed electrical contact regions 323 of the heater contacts 322 are exposed at the distal end, for example refer to Figure 2. Other configurations are envisaged, for example at least one exposed electrical contact region 323 may additionally or alternatively be defined along a minor longitudinal face or edge of the article 300, and on a major face of the article defined by the aerosol generator 304. The aerosol generator 304 is schematically shown in cross section in Figure 7.

[0182] The aerosol generator 304 is an implementation of the aerosol generator 304 of the aerosol provision system 100 described above.

[0183] The aerosol generator 304 comprises an aerosol generating layer 330. The aerosol generating layer is also known as an aerosolisable layer. The aerosol generating layer 330 comprises the aerosol generating material 302. The aerosol generator 304 comprises a resistive heating layer 340. The resistive heating layer 340, in embodiments, is formed as an electrically conductive layer. The aerosol generating layer 330 is on the resistive heating layer 340. The aerosol generating layer 330 is in direct contact with the resistive heating layer 340. In embodiments, the aerosol generating layer 330 is in indirect contact with the resistive heating layer 340. The resistive heating layer 340 may in embodiments comprise a coating. As described in detail below, the resistive heating layer 340 comprises a plurality of resistive heating elements 342, for example as shown in Figures 8 and 9. The or each resistive heating element 342 forms at least a portion of an electrically conductive path between a pair of the electrical contacts 322. The or each resistive heating element 342 provides the electrically conductive path for resistive heating of at least of portion of the aerosol generating material 302 to generate an aerosol. The aerosol generating material 302 is, in embodiments, in the form of a film or a gel.

[0184] The resistive heating layer 340 is formed as an electrically conductive layer. This layer in embodiments takes the form of at least one of a metal layer, such as an aluminium layer, or a non-metallic material, such as graphene. The resistive heating layer 340 is in the form of a foil, for example an aluminium foil.

[0185] The aerosol generator 304 comprises a support 350. The support 350 in embodiments comprise a paper or card material. The support 350 provides structural support for the aerosol generator 304. The resistive heating layer 340 is on the support 350. The support 350 is configured as a support layer. As shown in Figure 7, in the aerosol generator 304, the resistive heating layer 340 is sandwiched between the support 350 and the aerosol generating layer 330.

[0186] The support 350 is electrically insulative. The resistive heating layer 340 and the support layer 350 define a substrate 352. The substrate 352 supports the aerosol generating layer 330.

[0187] The article 300 may comprise a laminate 354 comprising the resistive heating layer 340 and the support layer 350. In embodiments, the laminate 354 comprises the aerosol generating layer 330. The aerosol generating layer 330 may be formed as a contiguous configuration, or may be formed from discrete portions. The discrete portions may comprise one or more of dots, strips, spirals, or other shapes.

[0188] In embodiments, the aerosol generating layer 330 comprises an aerosolgenerating film. In embodiments, the aerosol generating layer 330 comprises a plurality of aerosol-generating films. In embodiments, the aerosol-generating film comprises a plurality of aerosol-generating film regions. Such plurality of aerosol-generating films and / or plurality of aerosol-generating film regions may have different properties, for example at least one of different compositions, thicknesses, density, active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

[0189] One or more of the aerosol generating layer 330, resistive heating layer 340 and the support layer 350 may comprise a further layer. For example the support layer 350 may comprise a backing layer or an intermediate layer. The support layer 350 in embodiments is omitted.

[0190] Figure 8 shows one of the resistive heating elements 342. The resistive heating layer 340 comprises a plurality of resistive heating elements 342. In embodiments, the resistive heating layer 340 comprises a single resistive heating element 342.

[0191] The plurality of heating elements 342 may be formed in an array 344 as shown in Figure 9. Other configurations are envisaged.

[0192] The resistive heating element 342 comprises a resistive heating path. The resistive heating path is formed by an electrically conducting path. The resistive heating path is non-straight. The resistive heating path is convoluted. The configuration of the resistive heating path may vary. The electrical resistance of the heating element 342 may be dependent on the nature of the resistive heating path in the conductive layer, for example the length, width, thickness and arrangement of the path.

[0193] The resistive heating element 342 extends between a first type of electrical contact 360 and a second type of electrical contact 365. The first type of electrical contact 360 is configured to provide a positive contact and the second type of electrical contact 365 is configured to provide a negative contact. Electrical current flows between the first type of electrical contact 360 and the second type of electrical contact 365 through the path. The contact arrangement may be reversed. The first and second types of electrical contacts 360, 365 are heater electrical contacts 322. The first and second types of electrical contacts 360, 365 form at least part of the article electrical contact configuration 320.

[0194] The meandering or serpentine nature of the path of the resistive heating element 342 is such that the electrical resistance of the path is increased when compared with a straight path between the first and second type of electrical contacts. The resistive heating layer 340 may comprise a first type of electrical track 361 extending from the resistive heating element 342. The first type of electrical track 361 comprises the first type of electrical contact 360. The electrical contact 360 of the first type is configured to electrically connect with the device electrical connector 230. The first type of electrical contact 360 comprises a first type of exposed contact region 362. The first type of exposed contact region 362 is exposed on the article for direct connection with the device electrical connector 230.

[0195] The resistive heating layer 340 may comprise a second type of electrical track 366 extending from the resistive heating element 342. The second type of electrical track 366 comprises the second type of electrical contact 365. The electrical contact 365 of the second type is configured to electrically connect with the device electrical connector 230. The second type of electrical contact 365 comprises a second type of exposed contact region 367. The second type of exposed contact region 367 is exposed on the article 300 for direct connection with the device electrical connector 230.

[0196] As discussed in detail below, the conducting path of the resistive heating element 342 in embodiments is created by defining at least one electrically insulative barrier 346 in the resistive heating layer 340. In embodiments, the electrically insulative barrier 346 is formed by cutting electrically insulative barrier restrictions (i.e. electrically insulating portions), such as gaps, channels or slots into a sheet formed of electrically conductive material to form the resistive heating layer 340. In embodiments, the resistive heating layer 340 is preformed to define the or each resistive heating element 342 and then applied to the support 350. In embodiments, the resistive heating layer 340 is applied to the support 350, and the or each resistive heating element 342 then defined in the resistive heating layer 340. The or each restive heating element 342 defining the resistive heating layer 340 may be a printed heater. The insulative barrier may be an air gap. In embodiments, the insulative barrier is a filled gap, for example filled with an insulative material. The barrier defines a barrier to electrical conduction across the barrier.

[0197] The or each resistive heating element 342 defining the resistive heating layer 340 may be formed by a cutting action. Cutting may include die cutting. The resistive heating element may be formed by an action applied to the resistive heating layer only. In embodiments, the resistive heating element may be formed by an action applied to the resistive heating layer and the support layer, for example an action of cutting the resistive heating layer and the support layer.

[0198] The at least one electrically insulative barrier 346 defines the first and second types of electrical track 361 , 366.

[0199] In some embodiments, the tracks of the or each resistive heating element 342 have a width in the region of 0.5mm to 1mm (two example prototypes have widths of 0.93mm and 0.72mm respectively) and gaps between the tracks of less than about 0.25mm (the same two example prototypes have gaps of 0.2mm and 0.05mm respectively). The or each resistive heating element 342 may have overall dimensions of the order of 10mm x 10mm. Other dimensions are possible in other example embodiments. By forming the or each resistive heating element 342 of these dimensions from an aluminium foil of having a thickness of 0.006mm and an electrical resistivity of between 2 and 6 pOhmcm, the resistance of the path has been calculated to be of the order of 1 Ohm. In one example embodiment, the resistance was measured at between 0.83 and 1.31 Ohms.

[0200] As shown in Figure 9, the resistive heating layer 340 may be formed into a plurality of resistive heating elements, indicated generally by the reference numerals 342a, 342b, 242c, 342d and 342e. Each of the resistive heating elements 342a-342e extends from a respective one of the first type of electrical contact, indicated generally by the reference numerals 360a, 360b, 360c, 360d and 360e to a single second type of electrical contact 365. The number of electrical contacts may vary. As such, each resistive heating element 342a-342e extends between a discrete first type of electrical contact and a common second type of electrical contact. Each of the resistive heating element 342a-342e provides an electrically conductive path for resistive heating of a portion of the aerosol generating material 302 to generate an aerosol at the respective portion of the aerosol generator 304.

[0201] The separate first type 360a-360e of electrical contacts enable an electric current to be individually provided to each of the plurality of resistive heating elements 342a- 342e. The heating of different zones of the aerosol generating layer 330 can be controlled. For example, an aerosol generator may be provided with five aerosol generating zones. The resistive heating layer 340 allows each of those zones to be activated separately. Accordingly, for example, five puffs of aerosol may be generated from a single consumable incorporating a single aerosol generator 304, and ten puffs of aerosol may be generated from a single consumable incorporating two aerosol generators 304.

[0202] In the example resistive heating layer 340, the plurality of first type of electrical contacts 360a-360e, for example a positive electrical connection, are provided and a single second type of electrical contact 365, for example a negative electrical connection is provided. This is not essential to all implementations. For example, multiple contacts of the second type could be provided. In embodiments each resistive heating element 342a-342e comprises a corresponding one of the first type of electrical contact 360 and a corresponding one of the second type of electrical contact 365.

[0203] In the shown embodiment of Figure 9 of the resistive heating layer 340, the first type of electrical contacts 360a-360e are arranged on a first edge 363 of the resistive heating layer 340 and the second type of electrical contact 365 is arranged on a second edge 368 of the resistive heating layer 340. This may allow for convenient connection of electrical power, but, of course, many other configurations are possible, some of which are discussed further below.

[0204] The article 300, as shown in Figure 2, is now described in further detail with particular reference to the flow path and the exposed electrical contact region of a first type 362 and the exposed electrical contact region of a second type 367, refer to Figure 4.

[0205] The flow path is configured such that it is substantially free from overlap with the exposed electrical contact region of the electrical contacts 322, hereinafter referred to as the exposed electrical contact regions 362, 367. Each of the exposed electrical contact regions 362, 367 against which a device contact of a device connector is configured to abut does not substantially map onto any portion of the flow path. It is to be understood that the flow path also includes the air inlet 314 and air outlet 318. In the present embodiment, such lack of overlap is achieved by arranging the air inlet 314 on a longitudinal side of the article, spaced longitudinally away from the exposed electrical contact regions 362, 367 which in turn are arranged toward the distal end of the article 300. Such an arrangement is shown schematically in Figure 26. The cross-hatched region 380 of Figure 26 represents the exposed electrical contact region of the electrical contacts 322. The flow path 326 is offset from the exposed electrical contact region of the electrical contacts 322. The exposed electrical contact region of the electrical contacts 322 does not extend over the internal space in the article along which air and / or aerosol can flow. The internal space is bounded by the body 324. The body defines walls 327 of the article. The exposed electrical contact region 362, 367 of the electrical contacts 322 overlaps the walls 327 of the article. The body walls 327 support the exposed electrical contact region 362, 367 of the electrical contacts 322. The body 324 comprises a body layer 325, and the body layer comprises part of a stack of body layers comprising the body. In this case, the air inlet 314 is defined by an area of reduced number of body layers. That is, the air inlet 314 is formed by the omission of particular body layer regions.

[0206] Figure 27 shows another embodiment of article 300, wherein the air inlet 314 is formed in the aerosol generator 304 whilst remaining substantially free from overlap with the exposed electrical contact regions 362, 367. The cross-hatched region 380 of Figure 27 represents the exposed electrical contact region of the electrical contacts 322. The air inlet 314 may be formed in the support layer 350 or substrate 352 and be longitudinally offset from the exposed electrical contact regions 362, 367, as shown by being offtset from the cross-hatched region 380. In some embodiments, there may be a second air inlet arranged in the article to increase the air flow through the article. The second air inlet may be arranged according to any of the embodiments described above. The second air inlet may or may not be substantially free from overlap with the flow path.

[0207] In the present embodiment, the air inlet 314 is positioned downstream of each of the exposed electrical contact regions 362, 367. By downstream, it is understood to mean that the air inlet 314 is located between the mouth end and each of the exposed electrical contact regions 362, 367. Further, in some embodiments each of the exposed electrical contact regions 362, 367 may be at the distal end or spaced along a longitudinal edge of the article 300. In the present embodiment, each of the exposed electrical contact regions 362, 367 is supported by the body 324. However, in some embodiments none or only one of the exposed electrical contact regions 362, 367 may be supported by the body 324.

[0208] It can be envisaged that if an overlap between the air passage and exposed contact regions were to be present, a force applied by the device connector electrical contacts 232 toward and / or onto the exposed contact regions could, at least partially, act on the flow path 326. For example, a force may act on a any portion of the article that defines a portion of the air passage and / or the air inlets 314 and / or the air outlets 318. In turn, this may lead to any or all features forming the flow path 326 being deformed. By deformed, it is to be understood that the flow path 326 may be manipulated in some way such as to change its shape and / or the air flow properties therethrough. For example, a constricted region in the flow path 326 may be induced. Such deformation is undesirable since the flow properties through the article 300 may differ to those of a flow path 326 free of deformity. Therefore, by providing no substantial overlap between the flow path and each of the exposed electrical contact regions 362, 367, air and / or aerosol may flow more uniformly and consistently into and through the air passage. Importantly, the air and / or aerosol will flow through the article 300 for use as intended.

[0209] Figure 28 shows a further embodiment of the article 300. In the present embodiment, the flow path may be substantially free from overlap with the exposed electrical contact regions 362, 367 by laterally offsetting the flow path from exposed electrical contact regions 362, 367. The cross-hatched region 380 of Figure 28 represents the exposed electrical contact region of the electrical contacts 322. For example, the exposed electrical contact regions 362, 367 may arranged consecutively in the longitudinal direction, with the flow path arranged substantially parallel to the exposed electrical contact regions 362, 367 and longitudinal axis. It can be envisaged that the exposed electrical contact regions 362, 367 may be arranged such that they are not aligned in lateral and / or longitudinal direction but will remain substantially free from overlap with the flow path. This arrangement provides for an air inlet 314 at the distal end of the article 300 and an air outlet 301 at the proximal end. Such an arrangement may be desirable such that air flow through the article remains substantially laminar. By providing substantially laminar flow through the article 300, dispersion and / delivery of aerosol to a user may be more uniform. Further, a user may find drawing laminar flow through the article 300 requires less effort than turbulent flow. Of course, the air inlet may be formed through the aerosol generator 304. For example, through the support layer 350 or substrate 352.

[0210] Figures 29 and 30 show a further embodiment of the article 300. Figure 30 shows a perspective view of the article of Figure 29. In the present embodiment, the flow path 326 may be substantially free from overlap with the exposed electrical contact regions 362, 367 by offsetting the exposed electrical contact regions 362, 367 from the body 324. In this embodiment, the exposed electrical contact regions 362, 367 are positioned on a protruding panel 390 which extends away from the body 324. The cross-hatched region 380 of Figure 29 represents the exposed electrical contact region of the electrical contacts 322. As can be seen in Figures 29 and 30, the air inlet 316, flow path 326 and air outlet 318 are all substantially free from overlap with the exposed electrical contact region of the electrical contacts 322. Figures 29 and 30 are discussed in more detail below. Figure 10 is a flow chart showing part of a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 400, in accordance with an example embodiment.

[0211] The method or algorithm 400 starts at operation 402, where a resistive heating layer is formed into one or more heating elements (e.g. a plurality of heating elements), wherein each resistive heating element extends from an electrical contact of a first type to an electrical contact of a second type. In use, the or each heating element may be used to provide an electrically conductive path for resistive heating of a portion of an aerosol generating material to generate an aerosol. The formation of the or each resistive heating element may occur prior to or post application of the resistive heating layer on a support, where a support is present. The resistive heating layer may be adhered to the support, or mounted or formed on the support in a different configuration.

[0212] At operation 404, the formed resistive heating layer is placed in contact with the aerosol generating layer, wherein said aerosol generating layer incorporates aerosol generating material. Algorithm 400 may be used to produce the aerosol generator 304 described above.

[0213] Figure 11 shows the aerosol generator 304 being formed in accordance with an embodiment. The aerosol generating material 302 is formed on the resistive heating layer 340 by depositing aerosol generating material, for example by spraying, painting, dispensing or in some other way. The aerosol generating layer 330 is disposed on resistive heating layer 340 as indicated by the arrow 406, in an example implementation of the operation 404.

[0214] Figure 12 shows the resistive heating layer 340 being formed in accordance with an example embodiment. The resistive heating layer 340 is in the process of being cut using a laser cutter 408. The cutting of the resistive heating layer 340 can be used to form the paths of the heating elements described herein. The use of the laser cutter 408 (or some other cutting process) is not the only method by which the resistive heating layer 340 described herein may be generated. Some example methods are described below. Figure 13 is a flow chart showing part of a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 410. The method or algorithm 410 starts at operation 412, where the resistive heating layer is provided. At operation 414, one or more of the resistive heating elements are formed in the resistive heating layer by chemically etching the resistive heating layer. The operations 412 and 414 are an example implementation of the operation 402 of the method 400 described above. The aerosol generating material is then disposed on the resistive heating layer, thereby implementing the operation 404 described above.

[0215] Figure 14 is a flow chart showing part of a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 418. The method or algorithm 418 starts at operation 420, where one or more heating elements are formed, at least in part, by printing a resistive heating layer. The operation 420 is therefore an example implementation of the operation 402 of the algorithm 400 described above. The aerosol generating material is then disposed on the resistive heating layer, thereby implementing the operation 404 described above. The cutting, etching and printing methods described above are provided by way of example; other additional or alternative methods are also possible. For example, a so- called “hot foiling” approach could be used in which a heating element is made out of a resistive heating layer, and then assembled / bonded onto a support. Yet other techniques could be used, such as die cutting. Moreover, two or more technologies could be combined (e.g. electrical conductivity could be added to connection traces by adding more conductive material, such as additional foil, printed material, etc.). The skilled person will be aware of many further technologies, or combinations of technologies, that could be used in implementations of the principles described herein.

[0216] Figure 15 is a flow chart showing method of operation or an algorithm, indicated generally by the reference numeral 424, in accordance with an example embodiment.

[0217] The method or algorithm 424 may, for example, be implemented using any of the aerosol generators described herein. The method or algorithm 424 is initiated when an instruction to activate heating is received in an instance of operation 426. In response to the instruction to activate heating, a determination is made (in operation 428) regarding whether a heating element is available. As discussed above, a plurality of heating elements may be provided. The operation 428 may involve determination which of the heating elements have been used and / or the corresponding available aerosol generating material used up.

[0218] If a heating element is available, the algorithm moves to operation 430, where an available heating element is used. As discussed above, heating elements may be individually controllable, for example by providing electrical power to individual heating elements. Once the operation 430 is complete, the algorithm terminates at operation 432. If, at operation 428, a determination is made that no heating elements are available, for example because all heating elements have been used, then the algorithm terminates at operation 432. This may mean that a consumable part being used to implement the algorithm 424 needs to be replaced. Figure 16 shows the resistive heating layer 340 being formed in accordance with an embodiment. The resistive heating layer 340 is being cut using the laser cutter 408, although other methods could be used, such as chemical etching or printing, as discussed above. The cutting of the electrically conductive layer 340 forms the heating elements as described herein.

[0219] In the embodiment of Figure 16, the paths cut are linear paths, extending along the length of the electrically conductive layer 120.

[0220] Figure 17 shows another embodiment of the resistive heating layer 340. The resistive heating layer 340 may be formed using the laser cutter 408 described above, or some similar device or another method. The resistive heating layer 340 comprises a plurality of resistive heating elements 342, each resistive heating element 342 being a linear heating element comprising a conducting path extending along a length of the resistive heating layer 340. Each resistive heating element 342 extends from one of the first type of electrical contact 360, for example a positive electrical connection to one of the second type of electrical contact 365, for example a negative electrical contact. In such an embodiment, both types of electrical contact are provided at the same end of the resistive heating layer 340 and are provided next to each other. In such an arrangement that there is free from a common second type of electrical contact as is some other embodiments; instead, each heating element has separate first and second types of electrical contacts.

[0221] Figure 18 shows another embodiment of the resistive heating layer 340. The resistive heating layer 340 may be formed using the laser cutter 408 described above, or some similar device or another method. The resistive heating layer 340 comprises a plurality of heating elements 342, each heater element 342 being a linear heating element comprising a conducting path extending along a length of the resistive heating layer 340. Each resistive heating element 342 extends from one of the first type of electrical contact 360, for example a positive electrical connection to the second type of electrical contact 365, for example a negative electrical contact. In such an embodiment, the different types of electrical connection are provided at the opposite ends of the resistive heating layer 340 and a common second type of electrical contact is provided. Although a linear path is provided, an increase in the electrical resistance may be provided by means of providing a crenelated path, acting as a convoluted path. Note that the paths of any other embodiments described herein could also be crenelated.

[0222] Figure 19 shows the distal end of the article 300. As shown, the body 324 comprises a plurality of body layers 325. The body layers 325 are arranged in a stack of body layers 325. The body layers 325 form a laminate. The body layers 325 in embodiments are card layers. Other suitable materials may be used. The body layers 325 are configured to define features of the article 300. At least one body layer in embodiments comprises a gap defining the air inlet 315. The gap defines the opening 314. The aerosol generator 304 comprises the resistive heating layer 340. The resistive heating layer 340 comprises the resistive heating elements 342, the first type of electrical contacts 360, for example providing positive electrical connections to each of a plurality of heating elements 342 and a single second type of electrical contact 365, for example providing a common negative electrical connection to the plurality of heating elements 342. The first and second types of electrical contacts 360, 365, namely the heater contacts 322, together form at least part of the article electrical contact configuration 320 of the aerosol generator 304.

[0223] The resistive heating elements 342 are on an inner side of the resistive heating layer 340. The inner side defines the first side 306 of the aerosol generator 304 as shown in Figure 3. The heater contacts 322 are on the second side 307 of the resistive heating layer 340. The second side 307 defines an outer side of the aerosol generator 304. The heater contacts 322 are exposed so that they are able to be brought into contact with the device electrical connector 230. The heater contacts 322 are on an opposing side of the resistive heating layer 340 to the resistive heating elements 342. Other configurations are envisaged.

[0224] The support layer 350 is between an inner portion of the resistive heating layer 340 and an outer portion of the resistive heating layer 340.

[0225] A fold 370 is formed in the resistive heating layer 340. The fold 370 defines the heater contacts 322. The fold 370 as shown in Figures 2 to 4 and 19 extends perpendicular to the longitudinal axis of the aerosol generator 304. The fold 370 defines a flap 372. The heater contacts 322 are on the flap 372. The flap defines a contact panel. The remaining part of the blank defines a main panel.

[0226] In embodiments with the support layer 350, the support layer 350 in embodiments is folded. The substrate 352 is folded at the fold 370. In embodiments, the support layer 350 ends at the fold. In embodiments, the fold 370 extends parallel to the longitudinal axis of the aerosol generator 304.

[0227] The folded portion of resistive heating layer 340 is affixed in the folded position. This folded portion in embodiments is adhered, for example by bonding. Other fixing means are anticipated. The fold 370 defines the first type of exposed contact region 362. The fold 370 defines the second type of exposed contact region 367. The electrical tracks 361, 366 electrically communicate across the fold 370. The heater contacts 322 of the first type of electrical track 361 and the second type of electrical track 366 are defined on the second side of the resistive heating layer 340. Portions of the first type of electrical track 361 and the second type of electrical track 366 extend on the first side of the resistive heating layer 340. In embodiments the resistive heating elements extend from the fold 370. Other configurations are anticipated.

[0228] The device 200 comprises a plurality of connector electrical contacts 232 of the electrical connector 230. The configuration of the device connector 230 is dependent on the configuration of the heater contacts 322 of the aerosol generator 304. In embodiments, such as the aerosol generator as shown in Figure 19, the aerosol generator 300 comprises a plurality of heater contacts 322 including a plurality of the first type of heater contact 360 and one of the second type of heater contact 365. The article 300 comprises another set of heater contacts 322 on the opposing side of the article 300 corresponding to the second aerosol generator 304. Figure 20 shows a device connector 230 of the aerosol provision device 200 used in some embodiments. The connector 230 has separate connector electrical contacts 232 for connection with the heater contacts 322.

[0229] Figure 21 schematically shows the aerosol provision system 100. The system 100 comprises the article 300 and aerosol provision device 200, both shown in block diagram. The device 200 comprises first and second connectors 230a and 230b.

[0230] The connectors 230a and 230b enable the aerosol provision device 200 to provide regulated or controlled electrical voltages and / or currents to the various first and second type of heater contacts 360, 365 of the aerosol generator 304 when the article 300 is inserted into the aerosol provision device 200. The aerosol provision device 200 may comprise a connector arrangement configured to provide electrical power to the connectors 230a, 230b. The aerosol provision device 200 may, for example, operate the method as described above.

[0231] Figure 22 is a flow chart showing a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 440, in accordance with an example embodiment.

[0232] The method or algorithm 440 starts at operation 442, where a resistive heating layer is formed into at least one resistive heating element, the or each heating element providing an electrically conductive path for resistive heating of at least a portion of an aerosolisable material to generate an aerosol. Example heating elements that may be formed in the operation 442 are described elsewhere in this document. At operation 442, an aerosol generating material is applied and / or formed on the resistive heating layer.

[0233] The operations 442 and 444 of the method or algorithm 440 are similar to (and may be identical to) the operations 402 and 404 of the method or algorithm 400 described above.

[0234] In operation 446 at least one first type of electrical contact is provided on the resistive heating layer. The method of formation may be any of the methods described above. In operation 448 at least one second type of electrical contact is provided on the resistive heating layer. The method of formation may be any of the methods described above.

[0235] In embodiments, the first and second types of electrical contact are formed along or proximal a single edge of the resistive heating layer. In embodiments, the first and second types of electrical contact are formed along or proximal to different edges of the resistive heating layer. In embodiments, the first types of electrical contact (e.g. positive connection(s)) are provided along a first edge of the resistive heating layer. In embodiments, the second types of electrical contact (e.g. negative electrical connection(s)) are provided along a second edge of the resistive heating layer. The operations 446 and 448 could be performed in a different order, or at the same time. Moreover, the operations 446 and 448 could be performed together with the operation 442.

[0236] At operation 450, the resistive heating layer is folded. In embodiments, the support layer is folded together with the resistive heating layer. In embodiments, the resistive heating layer is folded such that electrical contacts of the first and second type are provided adjacent to one another, as discussed in detail below. Figures 23 to 25 show an embodiment of the aerosol generator 304 being formed in accordance with the algorithm 440.

[0237] Figure 23 shows another embodiment of the aerosol generator 304 being formed. The resistive heating layer 340 is being cut using a laser cutter 408. The pre-folded configuration defines a blank for forming the aerosol generator 304. The blank in embodiments defines fold lines along which folds are made during formation of the aerosol generator. The aerosol generator 304 blank comprises the resistive heating layer 340 and the support layer 350. The resistive heating layer 340 and the support layer 350 define panels defined by the fold lines.

[0238] As shown in Figure 23, the resistive heating layer 340 is formed into a plurality of heating elements 192, although the number may differ and may be one. A plurality of the first type of the electrical contact 360 (e.g. positive electrical contact) are provided along the first edge of the electrically conductive layer (one contact for each heating element is shown). A single second type of electrical contact 365 is provided along the second edge of the resistive heating layer 340. In embodiments the contacts are spaced from the edges. As discussed above, each heating element of the plurality extends from an electrical contact of the first type to an electrical contact of the second type.

[0239] The cutting of the resistive heating layer 340 by the laser cutter 408 forms the paths of the or each heating element 342. As discussed above, laser formation or some other cutting process is not the only method by which the resistive heating layer 340 described above may be generated. Some example alternative methods include chemical etching and printing.

[0240] As indicated in Figure 24, the aerosol generating layer 200 is provided on the resistive heating layer 340. The blank is then folded, as indicated by the arrows in Figure 24. In this embodiment, the folds are formed parallel to a longitudinal direction of the aerosol generator 304. Two folds are formed. A first panel 375 is defined comprising the heating elements 342. A second panel 376 is formed comprising the plurality of the first type of the electrical contact 360. A third panel 377 is formed comprising the second type of electrical contact 365. The aerosol generating layer 330 is on the first panel 375. Figure 25 shows the folded aerosol generator 304.

[0241] Figure 30 is embodiment of article 300 as briefly described above with reference to Figure 29. In this embodiment, the article 300 comprises the aerosol generator 304, which may be any aerosol generator described above, and a body 324 partially defining the flow path 326 along which aerosol can flow in the article 300. The article 300 comprises the first type of electrical contact 360 and the second type of electrical contact 365 wherein the resistive heating element is at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact.

[0242] In the present embodiment, the first type of electrical contact 360 and the second type of electrical contact 365 is offset from the body 324. As shown in Figure 30, this is achieved by the article 300 having a protruding panel 390, acting as a protruding member, protruding from the body 324 with the first type of electrical contact 360 and second type of electrical contact 365 being on the protruding panel 390. In embodiments only one or a limited number of the first type of electrical contact 360 and second type of electrical contact 365 are on the protruding panel 390.

[0243] In the present embodiment, the support 350 and resistive layer 340, which in combination define the substrate 352, extends beyond the body 324. In this case, the substrate 352 defines the protruding panel 390. However, in some embodiments, the protruding panel 390 may be a separate layer from the support 350. The protruding panel 390 is shown to protrude from a longitudinal end of the body. That is, the protruding panel 390 further elongates the article 300 beyond the body 324. In some embodiments, the protruding panel may protrude from a longitudinal side of the body. That is, the protruding panel extends the overall width of the article 300, beyond the body 324.

[0244] As shown in Figure 30, both the first type of electrical contact 360 and second type of electrical contact 365 are positioned on the protruding panel, thereby being offset from the body 324. The first type of electrical contact and second type of electrical contact are shown on the outer side of the protruding panel. The outer side of the protruding panel 390 being the side facing away from the body 324. However, the first type and second type of electrical contacts may be on the inner side of the protruding panel. The inner side of the protruding panel 390 being opposite the outer side of the protruding panel 390. The first type of electrical contact and second type of electrical contact in embodiments may be on different sides of the protruding panel. Only one of the electrical contacts need be on the protruding panel. One of the first type of electrical contact and second type of electrical contact may substantially overlap the body.

[0245] In the present embodiment, the air inlet 314 is located at the distal end of the article 300. In this embodiment, the air inlet 314 is aligned centrally with the longitudinal axis. In embodiments, the air inlet 314 may have a different configuration, for example in the side. In some embodiments, the air inlet 314 may be formed through the aerosol generator 304, as described above in relation other embodiments of the article 300. The air inlet 314 is shown with a rectangular cross-section. The air inlet 314 may have any shaped cross-section. For example, square, circular, oval, cruciform, pill-shaped or any other suitable shape.

[0246] The air flow to the air inlet 314 of the article 300 may be defined, for example by at least one of an air path through the device 200, an air path external to the device 200, and an air path between the device 200 and the article 300. An aerosol generated by the aerosol generator 304 exits the device at an aerosol outlet 318. In embodiments the aerosol outlet 318 is in the mouthpiece of the article 300, such that the aerosol is drawn directly from the article 300 into the mouth of a user of the device 200.

[0247] In some embodiments the air outlet 318 may be located at or toward the mouth end. In the use of the aerosol provision system 100, air is drawn into an air inlet 314 of the article 300. As shown in Figure 30, the protruding panel 390 is offset from the air inlet 316, thereby enabling the first type of electrical contact 360 and the second type of electrical contact 365 to be substantially free from overlap with the body 324, and in particular, substantially free from overlap with the air inlet 316. In this embodiment, the protruding panel 390 protrudes away from the air inlet 316 such to elongate the article 300 in the longitudinal direction. In some embodiments, the protruding panel 390 protrudes away from the air inlet 316 such to protrude in a lateral direction. That is, such to extend the width of the article 300 in the lateral direction.

[0248] In use, the device connector electrical contacts 232 may apply a force to the first type and second type of electrical contacts 360, 365. Whilst this force may be beneficial for coupling the device and the article, such force may be undesirable when directed toward and acting on the body 324 and / or any portion of the article defining the flow path. For example, when directed towards the air inlet 314. For example, a force applied by the device connector electrical contacts 232 to the body 324, in particular toward the air inlet 314, may cause deformation, for example compression, of the body 324 and / or air inlet 314.

[0249] In turn, this may lead to any or all of the features forming the flow path 326 being deformed. By deformed, it is to be understood that the flow path 326 may be manipulated in some way such as to change its shape and / or the air flow properties therethrough. For example, the flow path 326 may become deformed such that a constricted region is introduced. Such deformation is undesirable since the flow properties through the article 300 may differ to those of a flow path 326 free of deformity. Therefore, by providing no substantial overlap between the flow path and exposed electrical contact regions 362, 367, air and / or aerosol may flow more uniformly and consistently into and through the air passage. The air and / or aerosol will flow through the article 300 for use, as intended.

[0250] Such compression of the air inlet 314 may be particularly undesirable since it may reduce the volume of air that may be drawn into the article 300 with a single inhalation and / or require a user to inhale more deeply to draw in the same volume of air compared to an article with a non-compressed body and / or air inlet. This may detrimentally affect the effectiveness of the article 300.

[0251] By offsetting at least one of the first type of electrical contact and second type of electrical contact 360, 365 from the body, the force provided by the device connector electrical contacts 232 does not substantially act upon the body 324, and not upon on the air inlet 314. Further, this arrangement allows for a central air inlet to be present through the body at the distal end without the electrical connector electrical contacts 232 compressing the body 324 and / or air inlet 314. A central air inlet 314 at the distal end of the article 300 may be desirable such that air flow through the article remains substantially laminar, especially when the air outlet 318 is located centrally at the proximal end of the article. By providing substantially laminar flow through the article 300, dispersion and / delivery of aerosol to a user may be more uniform. Further, a user may find drawing laminar flow through the article 300 requires less effort than turbulent flow. Of course, the air inlet may be formed through the aerosol generator 304. For example, through the support layer 350 or substrate 352. The embodiments of article 300 shown in Figures 2 and 10 may form part of an aerosol provision system. The system further comprises an aerosol provision device 200, such as that shown in Figure 1, configured to receive at least a portion of the article 300. As described above, the aerosol provision device 200 comprises an electrical connector 230 configured to electrically connect with the first type of electrical contact and the second type of electrical contact. The electrical connector 230 comprises device electrical contacts 232 for contacting the first and second type of electrical contacts, thereby providing power from the device to the article.

[0252] In some embodiments, the device electrical connector is arranged such that, in use, the electrical connector, and in particular, the electrical connector contacts may be free from overlap with the flow path. That is, they apply a force directly onto the first and / or second type of electrical contacts, with the force being offset from the flow path through the article. In particular, the device electrical connector contacts do not apply a force directed substantially towards the flow path. Furthermore, in order to support the electrical connector contacts whilst in use, the electrical connector contacts may be arranged such that they overlap or overlay the body, if present. In doing so, the electrical connector contacts exert a force against the body, rather than on the flow path, thereby ensuring the force applied by the electrical connector contacts does not lead to deformation of the flow path.

[0253] It can be envisaged that other components of the electrical connector other than the electrical connector contacts may be in contact with, and therefore exert on, the article. In some embodiments, there may be means to allow the article be couplable to the electrical connector. For example, the electrical connector may comprise a member arranged opposite the electrical connector contacts and configured to grip the article therebetween. This member, or any other portion of the electrical connector, may be configured to not apply a force to the article directed substantially towards the flow path.

[0254] Figure 31 shows an aerosol provision device 200 and an article 300 according to non-limiting embodiment of the invention. The aerosol provision device 200 is substantially similar to that shown in Figure 1 and therefore only the additional features are described hereinafter. The article 300 shown in Figure 31 is shown as to be similar to the article 300 shown in Figure 29, except, as shown in Figure 31 the air inlet 316 is formed through the aerosol generator 304. In some embodiments, the aerosol provision device 200 could be arranged such to locate and be operable with any of the above described articles 300.

[0255] The aerosol provision device comprises a conduit 240 in the body 202 along which air can flow. A first opening 242 of the conduit 240 is configured as an opening in the device housing 204 and defines a device air inlet 244 through which air may be drawn, in use. In Figure 27, the device air inlet is shown on an exterior surface of the device housing 204. By exterior surface, it is understood to mean the surface gripped by a user, rather than an interior surface defined by the receptacle 208. A second opening of the conduit 240 is configured as an air outlet 248 in communication with the chamber 206.

[0256] As shown in Figure 31 , the device air inlet 244 and device air outlet 248 are longitudinally offset from each. In the present embodiment, this is achieved by providing two longitudinally offset conduits in fluid communication with each other. The device air inlet 244 and air outlet 246 could be direct fluid communication by a single conduit. The conduit 240 may take any suitable path between the device air inlet 244 and device air outlet 248. In some embodiments, the device air inlet 244 and device air outlet 248 may be longitudinally aligned. In such a case, the conduit 240 may be a single conduit. In any of the above cases, the conduit 240 may be a separate component or components, or it may be integrally formed with the device body 202 and / or housing 204. Within the receptacle 208 there is provided a sealing member 250. The sealing member 250 defines at least a portion of the conduit 240. The sealing member 250 is configured to sealably engage with the article 300 once the article 300 is, at least partially, received by the aerosol provision device 200. In particular, the sealing member 250 being configured to form a seal over the article air inlet 314. This may be achieved by the sealing member 250 being configured to align with the article air inlet 314, in use.

[0257] By sealably engage, it is to be understood that, when in use, substantially only air drawn in through the device air inlet 244 is received by the aerosol generating article air inlet 314. That is, in operation, the sealing member may provide a seal around the article air inlet 314, thereby defining a substantially closed air pathway between the device air inlet 314 and the article air outlet 318. The sealing member 250 is shown as tubular, comprising a wall 252 and a rim 254 for contacting, and sealing with, the article 300. The sealing member 250 may define the device air outlet 248.

[0258] As shown in Figure 31 , the sealing member 250 protrudes from the receptacle 208. That is, the sealing member 250 upstands from the interior surface of the receptacle 208, towards the longitudinal axis. In some embodiments the sealing member 250 may be configured to be resilient, such that, in use, the sealing member 250, or a portion thereof, may deform. For example, the wall 252 and / or rim 254 may deform. The sealing member 250 may comprise silicon to provide resilience. In some embodiments, the sealing member 250 may be configured such that it necessarily needs to deform during use. By allowing and / or requiring the sealing member 250 to deform in use, a better seal may be achieved than a rigid sealing member. The seal between the sealing member 250 and the article 300 may be further improved by tapering portions of sealing member 250, for example, the rim 254. This provides for further flexibility of the sealing member.

[0259] It can be envisaged that without such a sealing arrangement, such as that shown in Figure 31 , user inhalation and / or exhalation may cause condensation to form within the device 200, either within or outside the flow path. In particular, one problematic location where condensation may form is on the device electrical connector contacts 232. Condensation on the device electrical connector contacts 232 may cause a change in resistance of the electrical connectors themselves and / or affect the physical connection between the device electrical connector contacts 232 and the article contact regions. In turn, therefore, the power provided to the article 300, in particular aerosol generator 304, may be different than intended, hence affecting the efficacy of the article 300. It follows, therefore, that the problems relating to condensation in the device 300, in particular, on the device electrical connector contacts 232, may be obviated by isolating the flow path from the device electrical connector contacts 232. As described above, this may be achieved by providing a device sealing member 250 to sealably engage with the article 300.

[0260] As stated above, the aerosol provision device 200 could be arranged such to locate any of the above described embodiments of article 300.

[0261] The device 300 may comprise a second conduit 260 identical to that described above with reference to the first conduit 250, for example as shown in Figure 32. As shown in Figure 32, this allows for use with an article 300 with two air inlets. Figure 32 shows the conduit 260 comprises a second device air inlet 264 defined by a second opening in the housing 204 and a second device air outlet 268 in communication with the chamber 206. Further, there is shown a second sealing member 270 identical to the first sealing member 250. In this regard, the configuration of the first sealing member 250 described above and the advantages derived therefrom are equally applicable to the second sealing member 270. Further, the use of opposing sealing members may aid to locate the article in the receptacle. The first and second sealing members 250, 270 may differ. For example, the first and second sealing members 250, 270 may differ in cross- section size and / shape. The first and second sealing members 250, 270 may comprise different materials. As shown in Figure 32, the second conduit 270 is diametrically opposed to the first conduit 240. In particular, the first and second sealing members 250, 270 oppose each other. In some embodiments, the first and second conduits 240, 260 may differ. For example, the first device air inlet 244 and air outlet 348 may be longitudinally offset whilst the second device air inlet 264 and air outlet 268 are aligned. The first and second conduits 240, 260 may or may not be diametrically opposed.

[0262] In Figure 32, the second sealing member 270 is shown to protrude from the receptacle 208 and opposes the first sealing member 260. As discussed above, the first and second sealing members may or may not diametrically oppose each other. By arranging the first and second sealing members 250, 270 in opposition, means are provided for locating and / or gripping the article 300 therebetween. As shown in Figure 32 the electrical connector 230 may grip the article 300 by virtue of the device electrical connector contacts 232 exerting a force onto the article electrical contacts. However, the grip provided by the device electrical connector contacts 232 and article contacts may or may not be sufficient to retain the article 300 within the receptacle 208. Therefore, the opposing first and second sealing members 250, 270 may provide further retention means. The first and second sealing members 250, 270 may have additional benefits beside gripping and / or locating the article 300 within the receptacle 208. For example, the first and second sealing members 250, 270 may provide support for the article. That is, the first and second sealing members 250, 270 may restrict and / or prevent the article from unwantedly twisting or generally moving within the receptacle 208. Such movement may cause bending and / or weakening of the article whilst engaged with the device electrical connector 230. Further, movement may reduce the reliability of the electrical connection between the article 300 and device 200.

[0263] It may be desirable to detect use of the aerosol provision system. For example, an aerosol generating article 300 may become exhausted after a certain number of and / or durations of typical inhalations, and it be desirable to communicate this to a user. By detecting and storing use data, the device may be configured to provide feedback to a user. This may be achieved by providing a sensor configured to detect a change in air flow in the first 240 and / or second conduit 260, for example. A detection of change in air flow may be indicative of use. The sensor may be an acoustic sensor, for example, a microphone. The sensor may be a puff detector. The sensor may be located proximate or within the conduit. Additionally, or alternatively, the sensor may be an air pressure sensor located within the conduit to detect a change in flow. By providing the sensor in the conduit a more reliable detection of an attribute may be realised. As stated above, the aerosol provision device 200 could be arranged such to locate and be operable with any of the above described embodiments of article 300. An example device electrical connector 230 which may be used in an aerosol provision device in Figures 31 and 32 and used with any of the above described articles 300 is now detailed, with reference to Figure 20. As briefly described above, the device electrical connector 230 comprises a series of device electrical connector contacts 232 for providing power to the article electrical contacts. Each of the device electrical connector contacts 232 is configured to resiliently deflect upon engagement with article 300. In Figures 31 and 32, the device electrical connector contacts 232 will deflect upon engagement with the protruding panel 390 on which the article electrical contacts are situated 320. The device electrical connector contacts 232 may be configured to engage with any of the above described articles 300. In some embodiments, the device electrical connector contacts 232 may first engage with another portion of the article 300. For example, the device electrical connector contacts may deflect upon engagement with the body 324. In Figures 20, 31 and 32, the electrical connector contacts are sprung lever connections. Each device electrical connector contact 232 is shaped such to have a leading portion for initially engaging with the protruding panel and a curvilinear portion which is in contact with an article electrical contact, in use. As shown in Figures 20, 31 and 32, the leading portion is primarily curved and angled relative to the longitudinal-lateral plane. In some embodiments, the leading portion may be linear. By angling the leading portion 238 as shown, the resistance to coupling is reduced, therefore the force required to couple the device and article may be reduced. Furthermore, by reducing the force required by a user to couple the device 200 and article 300, the risk of damaging the device and / or article during insertion is also reduced since smaller forces are acting the device and / or article components. The aerosol provision device 200, and in particular, the device electrical connector contacts may be configured to provide electrical power to any of the above described articles 300. For example, articles 300 wherein the exposed electrical contact regions 320 are not on a protruding panel.

[0264] In some embodiments of the different arrangements of aerosol generators and articles described above the aerosol generating material is formed in a configuration other than as an aerosol generating layer. The aerosol generating material in embodiments is in the form of an aerosol generating segment. The aerosol generating segment generally comprises a solid material. Such a solid material may be shredded tobacco. The aerosol generating material, arranged as an aerosol generating segment for example, may comprise a plurality of individual pieces of aerosol generating material. The aerosol generating material may be individual pieces of tobacco material. In embodiments, the aerosol generating material comprises a plurality of strips, beads or pellets. In embodiments the aerosol generating segment is a plug of material.

[0265] The aerosol generating segment in embodiments comprises a body of material. The aerosol generating material is a non-liquid. In such an embodiment, the body of material comprises a rod of aerosol generating material, for example a tobacco rod. For example, the body of material may comprise shredded tobacco material. The body of material may be formed into a rod. In some embodiments, the body of material comprises cut rag tobacco that is formed into a rod. The aerosol generating material may comprise tobacco material. The aerosol generating material may comprise extruded tobacco. The aerosol generating material may comprise reconstituted tobacco.

[0266] The aerosol generating material, formed as a solid material, may comprise nicotine. The aerosol generating material may comprise, consist of, or essentially consist of, tobacco. In embodiments, the aerosol generating material is free from tobacco.

[0267] In embodiments of any of the above, the heating of the article provides a relatively constant release of volatile compounds into an inhalable medium. In an embodiment of the above, the aerosol generating segment is a plug of material. The article may comprise a mouth end section. A tubular element may be located between the aerosol generating material and the mouth end section. The article may comprise a ventilation area in the mouth end section. The mouth end section may define a mouthpiece configured to be placed between a user’s lips.

[0268] In embodiments of any of the above described articles, the or each resistive heating element is configured to heat substantially the entire aerosol generating material. The aerosol generating segment in embodiments is at least substantially cylindrical. In embodiments, the aerosol generating segment is at least partially wrapped by the resistive heating layer. In embodiments, the resistive heating element extends in the aerosol generating segment. The resistive heating element may extend around the aerosol generating segment. In embodiments, the resistive heating element encircles the aerosol generating segment. In some arrangements at least a portion of the flow path through the article is through the aerosol generating segment. The aerosol generating segment may define part of the air path. In embodiments, the first type of electrical contact and the second type of electrical contact are exposed from the aerosol generating segment.

[0269] The aerosol generating material may comprise tobacco material as described herein, which includes a tobacco component. In the tobacco material described herein, the tobacco component may contain paper reconstituted tobacco. The tobacco component may also contain leaf tobacco, extruded tobacco, and / or bandcast tobacco. The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco can be formed from a mixture of forms of tobacco material, for instance a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and bandcast tobacco. In embodiments, the tobacco material comprises paper reconstituted tobacco or a mixture of paper reconstituted tobacco and leaf tobacco. In the tobacco material described herein, the tobacco material may contain a filler component. The filler component is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco. The filler component may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler component may also be an inorganic material such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate. The filler component may also be a non-tobacco cast material or a non- tobacco extruded material. The filler component may be present in an amount of 0 to 20% by weight of the tobacco material, or in an amount of from 1 to 10% by weight of the composition. In some embodiments, the filler component is absent. In the tobacco material described herein, the tobacco material contains an aerosol-former material. In this context, an "aerosol-former material" is an agent that promotes the generation of an aerosol. An aerosol-former material may promote the generation of an aerosol by promoting an initial vaporisation and / or the condensation of a gas to an inhalable solid and / or liquid aerosol. In some embodiments, an aerosol-former material may improve the delivery of flavour from the aerosol generating material. In general, any suitable aerosol-former material or agents may be included in the aerosol generating material of the invention, including those described herein.

[0270] Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco feedstock is extracted with a solvent to afford an extract of solubles and a residue comprising fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after refining of the fibrous material, and optionally with the addition of a portion of non-tobacco fibres) by deposition of the extract onto the fibrous material. The process of recombination resembles the process for making paper.

[0271] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

Claims1 . An article for an aerosol provision device comprising: an aerosol generating material; a resistive heating layer comprising a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; the aerosol generating material being on the resistive heating layer; an exposed electrical contact region of a first type of electrical contact configured to electrically connect with an electrical connector of the aerosol provision device; an exposed electrical contact region of a second type of electrical contact configured to electrically connect with the electrical connector of the aerosol provision device; wherein the resistive heating element is at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact; an opening in the article defining an air inlet of a flow path along which aerosol is able to flow in the article; and wherein the exposed electrical contact regions are at least substantially free from overlap with the air path through the article.

2. The article of claim 1 , comprising a support wherein the resistive heating layer is on the support.

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

4. The article of claim 3, wherein the air inlet is defined by the body.

5. The article of claim 4, wherein the body defines a body wall and the air inlet is defined in the body wall.

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

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

8. The article of any of claims 2 to 6, wherein a majority area of each of the exposed electrical contact regions of a first type and a second type of electrical contact overlaps the support.

9. The article of claim 1 or claim 2, wherein the air inlet is formed through the resistive heating layer.

10. The article of claim 9, when dependent on claim 2, wherein the air inlet is defined in the support.

11. The article of any of claims 1 to 10, comprising an aerosol generating layer comprising aerosol generating material, wherein the aerosol generating layer is on the resistive heating layer..

12. The article of any of claims 1 to 11 , comprising a wrap configured to wrap around at least a portion of the article, wherein the air inlet is formed in the wrap and the at least one of the exposed electrical contact regions of the first type and the second type of electrical contact is free from overlap with the wrap.

13. An article for an aerosol provision device comprising: an aerosol generating material; a resistive heating layer; the aerosol generating material being on the resistive heating layer, wherein at least a portion of the resistive heating layer forms a resistive heating element configured to heat at least a portion of said aerosol generating material to generate an aerosol; a first type of electrical contact; a second type of electrical contact; wherein the resistive heating element is at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact; and a body at least partially defining a flow path along which aerosol can flow in the article;wherein at least one of the first type of electrical contact and the second type of electrical contact is offset from the body.

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

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

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

17. The article of claim 16, wherein the protruding panel protrudes from a longitudinal side of the body.

18. An aerosol provision system comprising: the article of any of claims 1 to 17; and an aerosol provision device configured to receive at least a portion of the article.

19. An aerosol provision device comprising; a body; a receptacle in the body defining a chamber configured to receive at least a portion of an aerosol generating article; a conduit in the body along which air can flow comprising an air outlet communicating with the chamber; a sealing member in the receptacle defining at least a portion of the conduit configured to sealably engage with an aerosol generating article in the chamber.

20. An aerosol provision system comprising: an article comprising aerosol generating material; and the aerosol provision device of claim 19.

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