CN118574530A

CN118574530A - Heating element for aerosol delivery system

Info

Publication number: CN118574530A
Application number: CN202280085439.1A
Authority: CN
Inventors: 詹姆斯·谢里登; 约瑟夫·彼得·萨顿
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-12-22
Filing date: 2022-12-09
Publication date: 2024-08-30
Also published as: CO2024007748A2; WO2023118791A1; MX2024007150A; US20250098763A1; CA3241074A1; JP2025500141A; IL313375A; AU2022422465A1; EP4451972A1; KR20240096866A

Abstract

The present invention relates to an aerosol-generating component comprising: a plurality of elongated heating portions extending between the plurality of end portions, wherein elongated apertures are provided between adjacent heating portions, wherein at least one elongated aperture is longitudinally tapered.

Description

Heating element for aerosol delivery system

Technical Field

The present invention relates to a delivery system, in particular to a non-combustible aerosol delivery system and components of the aerosol delivery system. The invention further relates to methods of generating and delivering aerosols using the non-combustible sol delivery systems and components disclosed herein.

Background

Non-combustible aerosol delivery systems that generate an aerosol for inhalation by a user are known in the art. Such systems typically include an aerosol generator capable of converting an aerosolizable material into an aerosol. In some cases, the aerosol generated is a condensed aerosol, wherein the aerosolizable material is first vaporized and then condensed into an aerosol. In other cases, the aerosol generated is an aerosol generated as a result of the aerosolization of the aerosolizable material. Such atomization may be achieved mechanically, for example by subjecting the aerosolizable material to vibration, to form small particulate material entrained in the gas stream. Alternatively, such atomization may be achieved electrostatically or otherwise (such as by applying pressure, etc.).

Since such aerosol delivery systems are intended to generate aerosols for inhalation by a user, the nature of the generated aerosols should be taken into account. These characteristics may include the size of the aerosol particles, the total amount of aerosol generated, etc.

In the case of using an aerosol delivery system to simulate a smoking experience (e.g. as a product of an e-cigarette or the like), control of these different characteristics is particularly important, as the user may desire to obtain a particular sensory experience through the use of the system.

It is desirable to provide an aerosol delivery system that better controls these characteristics.

Disclosure of Invention

According to a first aspect of the present disclosure there is provided an aerosol-generating component comprising: a plurality of elongated heating portions extending between the end portions, wherein elongated apertures are provided between adjacent heating portions, wherein at least one elongated aperture tapers longitudinally.

In some examples, a plurality of elongated apertures tapered longitudinally are provided in the aerosol-generating component.

In some examples, each elongated aperture is disposed between a respective pair of adjacent heating portions.

In some examples, at least two adjacent elongated apertures taper in opposite directions.

In some examples, the at least one heating portion has a substantially constant cross-section, wherein the cross-section is orthogonal to the length of the at least one heating portion.

In some examples, at least one elongated aperture is enclosed. In some examples, the at least one elongated aperture is enclosed within or by the periphery of the aerosol-generating component. For example, at least one elongated aperture may be surrounded by adjacent heating portions and opposite end portions.

In some examples, the elongated apertures have a maximum width of at most 2.0mm and/or a minimum width of at least 0.1 mm. The maximum width of the elongated apertures may be at most 1.8mm, or at most 1.6mm, or at most 1.5mm, or at most 1.4mm, or at most 1.2mm, or at most 1.0mm. The minimum width of the elongated apertures may be at least 0.2mm, or at least 0.3mm, or at least 0.4mm.

In some examples, the heating portions are arranged side-by-side. In some examples, the heating portion is part of a heating section of the aerosol-generating component.

In some examples, the aerosol-generating component is substantially planar.

In some examples, the aerosol-generating component is composed of a single layer.

In some examples, the aerosol-generating component is made of an electrically conductive material.

According to an aspect of the present disclosure, there is provided an aerosol-generating component comprising: a plurality of elongated heating portions extending between the end portions; wherein an elongated aperture is provided between adjacent heating portions, wherein at least one heating portion tapers longitudinally.

In some examples, the plurality of elongated heating portions are tapered longitudinally.

In some examples, at least two adjacent heating portions taper in opposite directions.

In some examples, at least one of the heating portions has a maximum width of at most 2.0mm and/or a minimum width of at least 0.1 mm. The maximum width of the heating portion may be at most 1.8mm, or at most 1.6mm, or at most 1.5mm, or at most 1.4mm, or at most 1.2mm, or at most 1.0mm. The minimum width of the heating portion may be at least 0.2mm, or at least 0.3mm, or at least 0.4mm.

In some examples, the heating portions are arranged side-by-side.

In some examples, the aerosol-generating component is substantially planar.

According to an aspect of the present disclosure, there is provided an article for use as part of a non-combustible sol supply system, the article comprising: an aerosol-generating component according to the preceding aspect; and one or more of a reservoir for an aerosolizable material and an aerosol-generating chamber.

In some examples, the aerosol-generating component is located at least partially in the aerosol-generating chamber.

In some examples, the reservoir is configured to provide the aerosolizable material to the aerosol-generating component.

In some examples, the reservoir is configured to hold a liquid aerosolizable material.

In some examples, the aerosol-generating component is biased against the aerosol-generating material delivery component.

According to an aspect of the present disclosure, there is provided a non-combustible sol supply system including: an article comprising an aerosol-generating component according to the previous aspect; and means comprising one or more of a power source and a controller.

It will be appreciated that the features and aspects of the invention described above in relation to the first and other aspects of the invention are equally applicable to, and may be suitably combined with, embodiments of the invention in accordance with the other aspects of the invention, and not just the specific combinations described above.

Drawings

Various embodiments will now be described in detail, by way of example only, with reference to the accompanying drawings, in which

In the figure:

Fig. 1 is a schematic representation of an aerosol provision system according to the present disclosure.

Fig. 2 is a schematic view of an article used as part of an aerosol supply system according to the present disclosure.

Fig. 3 is an exploded view of the article of fig. 2.

Fig. 4 is a sketch of an aerosol-generating component for use in the article of fig. 2 according to the present disclosure.

Fig. 5 is a schematic view of an aerosol-generating component for use in the article of fig. 2 according to the present disclosure.

Fig. 6 is a schematic view of an aerosol-generating component for use in the article of fig. 2 according to the present disclosure.

Detailed Description

Various aspects and features of certain examples and embodiments are discussed/described herein. Some aspects and features of certain examples and implementations may be conventionally implemented and are not discussed/described in detail for the sake of brevity. Thus, it should be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented by any conventional technique for implementing such aspects and features.

As described above, the present disclosure relates to, but is not limited to, non-combustible aerosol provision systems and devices that cause aerosol-generating material (which may also be referred to herein as aerosolizable material) to generate an aerosol without combusting the aerosol-generating material. Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (which use a combination of aerosol-generating materials to generate an aerosol). In some examples, the non-combustible aerosol supply system is an electronic cigarette, also referred to as a vapor electronic cigarette device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol generating material is not necessary in the present disclosure. In some examples, the non-combustible sol supply system is an aerosol-generating material heating system, also referred to as a heated non-combustion system. One example of such a system is a tobacco heating system. In some examples, the non-combustible aerosol supply system is a hybrid system that uses a combination of aerosol-generating materials to generate an aerosol, wherein one or more of the aerosol-generating materials may be heated. Each aerosol-generating material in such a mixing system may be, for example, in the form of a solid, liquid or gel, and may or may not contain nicotine. In some examples, the mixing system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, a tobacco or non-tobacco product.

In the following description, the terms "electronic cigarette" and "electronic cigarette" may be used at times; it should be understood, however, that these terms may be used interchangeably with the non-combustible sol (vapor) supply system or device as described above.

In some examples, the present disclosure relates to a consumable for holding an aerosol-generating material and configured for use with a non-combustible aerosol supply device. These consumables are sometimes referred to as articles of manufacture in this disclosure.

The non-combustible sol supply system generally includes a device portion (also referred to herein as a device) and a consumable/article portion (also referred to herein as an article). The device portion typically includes a power source and a controller. The power source may typically be a power source, such as a rechargeable battery.

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

In some examples, a consumable/article for use with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating material storage area (which may also be referred to herein as a reservoir for an aerosolizable material), an aerosol generating material delivery component (e.g., a core, such as a pad), an aerosol generator (which may also be referred to herein as an aerosol generating component), an aerosol generating area (which may also be referred to herein as an aerosol generating chamber), a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol modifier.

The systems described herein generally generate inhalable aerosols by vaporizing an aerosol-generating material. The aerosol-generating material may comprise one or more active components, one or more flavours, one or more aerosol-former materials and/or one or more other functional materials.

The aerosol-generating material may for example be in the form of a solid, liquid or gel, which may or may not contain an active substance and/or a flavouring. In some examples, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some examples, the amorphous solid may be a dried gel. Amorphous solids are solid materials that can retain some fluid (such as a liquid) within their interior. In some examples, the aerosol-generating material may comprise from about 50wt%, 60wt%, or 70wt% amorphous solids to about 90wt%, 95wt%, or 100wt% amorphous solids, for example.

The term "active substance" as used herein may relate to a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropic agents, psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active may include, for example, nicotine, caffeine, taurine, caffeine, vitamins (such as B6 or B12 or C), melatonin, or components, derivatives, or combinations thereof. The active substance may comprise one or more components, derivatives or extracts of tobacco or other plants.

The aerosol former material may comprise one or more components capable of forming an aerosol. In some examples, the aerosol former material may include one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1, 3-butanediol, erythritol, meso-erythritol, ethyl vanillic acid, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenyl acetate, glycerol tributyrate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

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

As used herein, the term "component" is used to refer to a portion, section, unit, module, assembly, etc. of an electronic cigarette or similar device that includes a plurality of smaller portions or elements that may be located within an outer housing or wall. The electronic cigarette may be formed or constructed from one or more such components, and the components may be removably or detachably connected to one another, or may be permanently joined together during manufacture to define the overall electronic cigarette. The present disclosure is applicable to, but is not limited to, systems comprising two components detachably connected to each other and configured, for example, as consumable/article components (also referred to herein as cartridges or aerosol-cartridges) capable of holding an aerosol-generating material, and a device/control unit having a battery for providing electrical power to operate elements for causing the aerosol-generating material to generate a vapor.

Fig. 1 is a highly schematic (not to scale) of an exemplary aerosol/vapor supply system, such as an electronic cigarette 10. The e-cigarette 10 may have a generally cylindrical shape extending along a longitudinal axis represented by a dashed line and includes two primary components, namely a control or power component or section 20 (which may also be referred to herein as a device) and a cartridge assembly or section 30 (which may also be referred to herein as an article, consumable, atomizer, or cartridge) that operates as a vapor-generating component.

The cartridge assembly 30 comprises a storage compartment (which may also be referred to herein as a reservoir) 3 containing an aerosolizable material containing, for example, a liquid formulation that will generate an aerosol, for example, nicotine. As an example, the aerosolizable material may comprise about 1% to 3% nicotine and 50% glycerin, with the remainder substantially comprising propylene glycol, and possibly other components, such as water or flavors. The storage compartment 3 has the form of a storage tank, which is a container or receptacle, in which the aerosolizable material can be stored such that the aerosolizable material is free to move and flow (if liquid) within the confines of the tank. Alternatively, the storage compartment 3 may contain a quantity of an adsorbent material (such as cotton wool or glass fibre) which retains the aerosolizable material within the porous structure. The storage compartment 3 may be sealed after filling during manufacture so as to be disposable after the aerosolizable material is exhausted, or the storage compartment may have an inlet port or other opening through which new aerosolizable material may be added. The cartridge assembly 30 further comprises an electronic aerosol-generating component 4 located outside the reservoir tank 3 for generating an aerosol by vaporizing the aerosolizable material. In various arrangements, the aerosol-generating component may be a heating element (heater) which is heated by passing an electrical current therethrough (via resistive heating or inductive heating) to raise the temperature of the aerosolizable material until the aerosolizable material is vaporised. A liquid conduit arrangement, such as a wick or other porous element (not shown), may be provided to convey the aerosolizable material from the storage compartment 3 to the aerosol-generating component 4. The core may have one or more portions inside the storage compartment 3 in order to be able to absorb the aerosolizable material and transfer it by wicking or capillary action to other portions of the core in contact with the aerosol-generating component 4. The aerosolizable material is thereby gasified and replaced by new aerosolizable material for delivery through the core to the aerosol-generating component 4.

The combination of heater and wick, or other arrangement of parts that perform the same function, is sometimes referred to as a nebulizer or nebulizer assembly. Various designs are possible in which the various parts may be arranged differently from the highly schematic illustration in fig. 1. For example, the wick may be a completely separate element from the aerosol-generating component, or the aerosol-generating component may be configured to be porous and capable of performing the wicking function directly (e.g., by taking the form of a suitable resistive mesh or capillary body).

In some cases, the conduit for transporting the liquid to generate the vapor may be formed at least in part by one or more slots, tubes or channels between the storage compartment and the aerosol-generating component that are sufficiently narrow to support capillary action to draw the source liquid from the storage compartment and transport the source liquid for gasification. In general, a nebulizer may be considered as an aerosol-generating component capable of causing an aerosolizable material delivered thereto to generate a vapor, and a liquid conduit (passageway) capable of delivering or transporting liquid from a storage compartment or similar liquid reservoir to the aerosol-generating component by capillary forces.

Typically, the aerosol-generating component is located at least partially within an aerosol-generating chamber that forms part of an airflow channel through the electronic cigarette/system. The vapour generated by the aerosol-generating component is fed into the chamber and as air passes through the chamber and over or around the aerosol-generating component, the air captures the generated vapour, which is thereby condensed to form the desired aerosol.

Returning to fig. 1, the cartridge assembly 30 further comprises a mouthpiece 35 having an opening or air outlet through which a user may inhale an aerosol generated by the aerosol-generating component 4 and delivered through the airflow channel.

The power component 20 comprises a battery pack or battery 5 (which may also be referred to herein as a battery, and which may be rechargeable) in order to provide power to the electrical components of the electronic cigarette 10, in particular the aerosol-generating component 4. In addition, there is a printed circuit board 28 and/or other electronic devices or circuits for controlling the electronic cigarette as a whole. When vapor is desired, the control electronics/circuitry connects the vapor-generating element 4 to the battery 5, for example, in response to a detected signal from a barometric pressure sensor or an airflow sensor (not shown) that is drawn on the system 10, during which air enters through one or more air inlets 26 in the wall of the power component 20 to flow along the airflow path. When the aerosol-generating component 4 receives power from the battery 5, the aerosol-generating component 4 vaporises the aerosol-generating material delivered from the storage compartment 3 to generate an aerosol, and the aerosol is then inhaled by the user through the opening in the mouthpiece 35. As the user draws on the mouthpiece 35, the aerosol passes to the mouthpiece 35 along an airflow path (not shown) connecting the air inlet 26 to the air outlet. Thus, an airflow path through the electronic cigarette is defined between one or more air inlets (which may or may not be located in the power component) of the atomizer and the air outlet at the mouthpiece. In use, the direction of air flow along the air flow path is from the air inlet to the air outlet, such that the atomizer can be described as being downstream of the air inlet and upstream of the air outlet.

In this particular example, the power section 20 and the cartridge assembly 30 are separate parts that are detachable from each other by being separated in a direction parallel to the longitudinal axis (indicated by solid arrows in fig. 1). When the device 10 is in use, the components 20, 30 are joined together by mating engagement elements 21, 31 (e.g., bolts, magnets, or bayonet fittings) that provide a mechanical and electrical connection between the power section 20 and the cartridge assembly 30. However, this is merely an example arrangement, and the various components may be distributed differently between the power section 20 and the cartridge assembly section 30, and may include other components and elements. The two sections may be connected together end-to-end in a longitudinal configuration as shown in fig. 1, or in a different configuration (such as a parallel side-by-side arrangement). The system may or may not be generally cylindrical and/or may not have a generally longitudinal shape. Either or both segments may be intended to be discarded and replaced when depleted (e.g., the reservoir is empty or the battery is low in power), or intended for multiple uses that can be achieved through actions such as refilling the reservoir, recharging the battery, or replacing the atomizer. Alternatively, the e-cigarette 10 may be an integral device (disposable or refillable/rechargeable) that cannot be separated into two or more parts, in which case all of the components are included within a single body or housing. Embodiments and examples of the present invention apply to any of these and other configurations as would be known to one of skill in the art.

As mentioned, aerosol-generating components of the type that may be used in the atomizing portion of an electronic cigarette (the portion configured to cause the source liquid to generate vapor), such as heating elements, combine the functions of heating and liquid delivery because they are electrically conductive (resistive) and porous. Note that, the conduction (resistance) referred to herein means that the component has the ability to generate heat in response to the flow of current therein. Such a flow may be provided by so-called resistive heating or inductive heating. Examples of suitable materials for such components are electrically conductive materials (such as metals or metal alloys) that are made in sheet form, i.e. planar shapes having a thickness that is many times smaller than their length or width. Examples in this regard may be a net, mesh, grid, or the like. The mesh may be formed of wires or fibers woven together or alternatively polymerized into a nonwoven structure. For example, the fibers may be polymerized by sintering, where heat and/or pressure is applied to the collection of metal fibers to compact them into a single porous body. The planar aerosol-generating component may define a curved plane and in these cases reference to the plane formed by the planar aerosol-generating component refers to an imaginary plane forming a best fit plane through the component.

These structures can provide voids and gaps of suitable size between the metal fibers to provide capillary forces for wicking liquid. Thus, these structures may also be considered porous due to their ability to absorb and distribute liquids. In addition, air can permeate through the structure due to the voids and gaps between the metal fibers. Furthermore, metals are electrically conductive and are therefore suitable for resistive heating, whereby the passage of an electric current through a material having an electrical resistance generates heat. However, this type of structure is not limited to metal; other conductive materials may also be formed into fibers and into a mesh, grid or net structure. Examples include ceramic materials, which may or may not be doped with substances intended to modify the physical properties of the mesh.

Such a planar sheet-like porous aerosol-generating member may be arranged within the electronic cigarette to be located within an aerosol-generating chamber forming part of the airflow channel. The aerosol-generating component may be oriented within the chamber such that the airflow through the chamber may flow in a surface direction, i.e. substantially parallel to the plane of the substantially planar sheet-like aerosol-generating component. Examples of such configurations can be found in WO2010/045670 and WO2010/045671, the entire contents of which are incorporated herein by reference. The air may then flow over the heating element and capture the vapor. Aerosol generation thus becomes very efficient. In an alternative example, the aerosol-generating component may be oriented within the chamber such that the airflow through the chamber may flow in a direction substantially transverse to the surface direction, i.e. substantially orthogonal to the plane of the substantially planar sheet-like aerosol-generating component. Examples of such configurations can be found in WO2018/211252, the entire contents of which are incorporated herein by reference.

The aerosol-generating component may have any one of the following structures: a woven or knitted structure, a mesh structure, a fabric structure, an open cell fibrous structure, an open cell sintered structure, an open cell foam or an open cell deposited structure. The structure is particularly suitable for providing aerosol-generating components having a high porosity. The high porosity may ensure that the heat generated by the aerosol-generating component is mainly used to vaporise the liquid and may achieve a higher efficiency. For the structure, a porosity of greater than 50% is contemplated. In one embodiment, the aerosol-generating component has a porosity of 50% or greater, 60% or greater, 70% or greater. For example, the open-celled fibrous structure may be composed of nonwoven fabrics that can be arbitrarily consolidated, and may also be sintered to improve bonding forces. For example, the open-cell sintered structure may be composed of a sintered composite material in the form of particles, fibers, or flocs produced by a film casting process. The open-pore deposition structure may be produced, for example, by a CVD process, PVD process, or by flame spraying. Open-cell foams are in principle commercially available and can also be realized in small pore designs.

In one embodiment, the aerosol-generating component has at least two layers, wherein the layers comprise at least one of the following structures: a plate, foil, paper, mesh, woven structure, fabric, open cell fibrous structure, open cell sintered structure, open cell foam or open cell deposited structure. For example, the aerosol-generating component may be formed from an electrically heated resistor (consisting of a metal foil) in combination with a structure comprising a capillary structure. Where the aerosol-generating component is considered to be formed from a single layer, such a layer may be formed from a wire fabric or a non-woven metal fibre fabric. The individual layers are advantageously, but not necessarily, connected to each other by a heat treatment, such as sintering or welding. For example, the aerosol-generating component may be designed as a sintered composite material consisting of a stainless steel foil and one or more layers of stainless steel wire fabric (material, such as AISI 304 or AISI 316). Alternatively, the aerosol-generating component may be designed as a sintered composite material consisting of at least two layers of stainless steel wire fabric. The layers may be connected to each other by spot welding or resistance welding. The individual layers may also be mechanically connected to each other. For example, a double layer silk fabric can be made by simply folding a single layer. Instead of stainless steel, it is also possible to use, for example, heating conductor alloys with a higher resistivity than stainless steel, in particular NiCr alloys and CrFeAl alloys ("Kanthal"). The material connection between the layers is achieved by a heat treatment, as a result of which the layers remain in contact with each other even under unfavorable conditions, for example during heating by the aerosol-generating component and the resulting thermal expansion. Alternatively, the aerosol-generating component may be formed by sintering a plurality of individual fibers together. Thus, the aerosol-generating component may be composed of sintered fibres (such as sintered metal fibres).

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

As mentioned above, the aerosol-generating component may be made of sintered metal fibre material and may be in the form of a sheet. Such materials may be considered as webs or irregular grids and are made by sintering together a randomly aligned arrangement or set of spaced apart metal fibers or strands. Single layer fibers or multiple layer fibers, for example up to five layers, may be used. As an example, the metal fibers may have a diameter of 8 μm to 12 μm, be arranged as a sheet of 0.16mm thickness, and be spaced apart to produce a material density of 100g/m ² to 1500g/m ² (such as 150g/m ² to 1000g/m ²、200g/m² to 500g/m ², or 200g/m ² to 250g/m ²) and a porosity of 84%. The sheet thickness may also be in the range of 0.1mm to 0.2mm, such as 0.1mm to 0.15 mm. Specific thicknesses include 0.10mm, 0.11mm, 0.12mm, 0.13mm, 0.14mm, 0.15mm, or 0.1mm. Generally, the aerosol-generating component has a uniform thickness. However, it will be appreciated from the following discussion that the thickness of the aerosol-generating component may also vary. This may be due to, for example, parts of the aerosol-generating component being subjected to compression. Different fiber diameters and thicknesses may be selected to vary the porosity of the aerosol-generating component. For example, the aerosol-generating component may have a porosity of 66% or greater, or 70% or greater, or 75% or greater, or 80% or greater, or 85% or greater, or 86% or greater.

The aerosol-generating component may form a substantially planar structure comprising a first surface and a second surface. The substantially planar structure may take the form of any two-dimensional shape, for example, circular, semi-circular, triangular, square, rectangular, and/or polygonal. Generally, the aerosol-generating component has a uniform thickness.

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

In case the aerosol-generating component is made of a resistive material, an electric current is allowed to flow through the aerosol-generating component to generate heat (so-called joule heating). In this regard, the resistance of the aerosol-generating component may be appropriately selected. For example, the aerosol-generating component may have a resistance of 2 ohms or less, such as 1.8 ohms or less, such as 1.7 ohms or less, such as 1.6 ohms or less, such as 1.5 ohms or less, such as 1.4 ohms or less, such as 1.3 ohms or less, such as 1.2 ohms or less, such as 1.1 ohms or less, such as 1.0 ohms or less, such as 0.9 ohms or less, such as 0.8 ohms or less, such as 0.7 ohms or less, such as 0.6 ohms or less, such as 0.5 ohms or less. Parameters of the aerosol-generating component, such as material, thickness, width, length, porosity, etc., may be selected to provide a desired electrical resistance. In this regard, a relatively low resistance will help to obtain higher power from the power source, which is advantageous in producing a higher aerosolization rate. On the other hand, the resistance should not be too low so as not to compromise the integrity of the aerosol generator. For example, the resistance cannot be lower than 0.5 ohm.

Planar aerosol-generating components (such as heating elements) suitable for use in the systems, devices and articles disclosed herein may be formed by stamping or cutting (such as laser cutting) a larger sheet of porous material into a desired shape. This may include punching out, cutting out or otherwise removing material to form openings in the aerosol-generating component. These openings can affect both the ability of air to pass through the aerosol-generating component and the tendency of the current to flow in certain areas.

Fig. 2 is a schematic diagram of an exemplary article 100 according to the present disclosure. The article 100 includes a housing. In this particular example, the housing includes an outer housing 110 and an inner housing 120. The outer housing 110 is formed by combining a first outer housing part 110a and a second outer housing part 110 b. The specific appearance of the outer case 110 is not limited, but in this specific example, the outer case 110 has a polyhedral surface. The housing (e.g., outer housing 110) may include at least one outlet 115. In this particular example, there are two outlets 115. The one or more outlets 115 are used to deliver the aerosol generated within the article 100 to the mouth of the user. Thus, in the example shown in fig. 2, outer housing 110 also forms the mouthpiece of the article.

The first outer housing part 110a mates with the second outer housing part 110b to form the outer housing 110. In this particular example, the components 110a, 110b are assembled together via a snap fit arrangement. In particular, the resilient tabs 111 on the second outer housing part 110b (only one side of which is visible in fig. 2) snap into corresponding receiving apertures 112 on the first outer housing part 110 a. It should be appreciated that the exact location of the tabs and apertures is not limited, and indeed, the tabs may be formed on the outer housing component 110a and the apertures may be formed on the outer housing component 110 b.

Referring to fig. 3, the first outer housing part 110a is shown separated from the second outer housing part 110b to expose the inner housing part 120, the aerosol-generating part 130 (which in this particular example is a resistive metal heater), the flow regulator 140 and the pad 150. The inner housing component 120 may be configured to define a storage area 121 for an aerosolizable material (not shown). The inner housing component 120 may be at least partially nested within the first outer housing component 110 a. The inner housing part 120 is possibly connected to the first outer housing part 110a (e.g. they may be attached together or be part of the same moulding). The inner housing component 120 may have an open end 122 that mates with the flow regulator 140. The open end 122 and the flow regulator 140 may together define a path for the aerosolizable material to flow from the storage region 121 to the pad 150. An optional mouthpiece (not shown) may be fitted over the outside of the first outer housing part 110a (or the outer housing may form the mouthpiece).

The flow regulator 140 may include a recess 141 into which the open end 122 of the inner housing component 120 may be received. The recess 141 may include one or more openings 142 that allow the aerosolizable material to flow through the flow regulator. In this particular example, the openings are slot-shaped, but it is understood that one or more of the openings may take on different cross-sections, such as circular, elliptical, or polygonal. Further, the cross-sectional area of the one or more openings may vary with the length of the flow regulator. Thus, the one or more openings may have a larger cross-sectional area at a location toward the liquid storage region than at a location toward the pad 150. The flow regulator 140 may include an annular seal 143 around its perimeter for inhibiting the flow of the aerosolizable material from the boundary between the inner housing member 120 and the flow regulator 140. The flow regulator 140 may include a surface against which the aerosol-generating component may be biased, and thus the flow regulator acts as a heater support in some cases.

The pad 150 may be made of a capillary material suitable for holding an aerosolizable material. Specifically, the pad 150 may become saturated with the aerosolizable material as the aerosolizable material flows through the flow regulator 140. However, due to the capillary nature of the pad 150, leakage of the aerosolizable material from the pad 150 is inhibited. The aerosol-generating component 130 may be located adjacent to the pad 150 such that when the aerosol-generating component 130 is energized (in this particular example, resistance heating), the aerosolizable material present in the pad 150 is evaporated. As explained above, the pad 150 and the aerosol-generating component 130 may be combined into a single component.

In this specific example, the aerosol-generating component 130 is arranged towards the second outer housing component 110b. Electrical contacts (e.g., pins) 116 on the outer housing component 110b may contact the aerosol-generating component 130 at electrical connections (e.g., tabs) 130C in order to allow current to flow through the aerosol-generating component 130 during actuation of the system.

The second outer housing component 110b can include at least one air inlet 117 that allows air to enter the article 100. During use, air may enter the article 100 via the at least one air inlet 117, whereby it mixes with the vapor generated from the aerosol-generating component 130. The aerosol thus produced may then be directed to the one or more air outlets 115 via at least one airflow channel 180 extending between the first outer housing component 110a and the inner housing component 120. For example, in this particular example, there are two air flow channels 180 that extend longitudinally along the length of the article 100 and cooperate with the air outlets 115 to form a flow path through the article.

According to one aspect, there is provided an aerosol-generating component comprising a material having grains, wherein the grains of the material are oriented substantially orthogonal to an axis on which electrical connections of the aerosol-generating component are located. By providing grains of material in this direction, the aerosol-generating component may be made more resistant to material failure or breakage, for example when the aerosol-generating component is forced to form a curved shape by bending the aerosol-generating component against the grain orientation (grain orientation, grain direction). Furthermore, the aerosol-generating component may be made more resistant to permanent deformation that might otherwise occur, for example when the aerosol-generating component is forced to form a curved shape by bending the aerosol-generating component against the grain orientation. It should be understood that "orientation of grains" refers to the orientation in which regions of material are aligned. Materials such as metals may be processed to include a particular grain orientation.

This aspect is most clearly shown in the sketch of fig. 4, where the orientation of the grains of material is indicated by the dashed lines. An exemplary aerosol-generating component 130 (which may have a grain orientation of this aspect) is shown in fig. 5 and 6 (but the grain orientation is not shown in fig. 5 and 6).

The axis on which the plurality of electrical connections of the aerosol-generating component are located may correspond to the first axis.

The material may have a crystalline structure. It should be appreciated that any suitable material may be used as known to those skilled in the art. For example, the material may be a conductive material. For example, the material may be a metallic material, e.g. a metal or a metal alloy, such as stainless steel. Other materials are also contemplated, such as nichrome and NiCrFe.

The orientation of the grains of material may be substantially orthogonal to the axis about which the aerosol-generating component 130 is bent (e.g., in use). Advantageously, this may help ensure that the curved form of the aerosol-generating component 130 is maintained. In this regard, the aerosol-generating component 130 may have a permanent curvature, or may be curved when assembled in an article in use (e.g., due to the connectivity and shape of its surrounding components). The axis about which the aerosol-generating component is curved may correspond to the second axis.

The aerosol-generating component 130 may be substantially planar. The aerosol-generating component 130 may be constructed from a single layer.

Each of the electrical connections 130C may be configured to connect to a respective electrical contact. The electrical connection 130C may be located on an axis.

It should be understood that the form and size of the electrical connection 130C may vary. For example, the or each electrical connection 130C may be configured to connect to a respective electrical contact 116. In this way, the aerosol-generating component 130 may be powered by a power source (such as a battery). The or each electrical connection 130C may be configured to be releasably or permanently connected to a respective electrical contact 116. The or each electrical connection 130C may be configured to connect to a respective electrical contact by a clearance fit, interference fit and/or transition fit. The or each electrical connection 130C may be configured to connect to a respective electrical contact 116 by press-fit. The electrical connection 130C provides a way in which the aerosol-generating component 130 may be electrically connected to a power source.

The aerosol-generating component 130 may include a heating section 130A and one or more electrical connections 130C. In various examples, the aerosol-generating component includes a heating section 130A and two electrical connections 130A, each electrical connection 130C being disposed at a respective opposite end of the heating section 130A. The heating section 130A may be considered to be part of the aerosol-generating component 130 which, in use, is heated to vaporise the aerosolizable material and generate an aerosol. The heating section 130A may be disposed between the plurality of electrical connections 130C. One or more elongated apertures 130B (which are also referred to herein as one or more longitudinal gaps 130B) may be provided in the aerosol-generating component 130, such as in the heating section 130A. The one or more elongated apertures 130B may help provide a "hot spot" generally around the end thereof where the aerosol-generating material may be rapidly vaporized. The aerosol-generating component 130 (e.g., heating section 130A) may comprise a plurality of elongate heating portions 130E that may be arranged side-by-side. The heating portions 130E may extend between the respective end portions 130F. An elongated gap 130B may be provided between adjacent heating portions 130E.

The aerosol-generating component 130 may be manufactured using a variety of different techniques as will be familiar to those skilled in the art. For example, various different material processing techniques may be used to orient grains of material as desired.

According to an alternative aspect, there is provided an aerosol-generating component comprising a material having grains, wherein the grains of the material are oriented substantially parallel to one or more elongate apertures within the aerosol-generating component. By providing grains of material in this direction, the aerosol-generating component may be made more resistant to material failure or breakage, for example when the aerosol-generating component is forced to form a curved shape by bending the aerosol-generating component against the grain orientation. Furthermore, the aerosol-generating component may be made more resistant to permanent deformation that might otherwise occur, for example when the aerosol-generating component is forced to form a curved shape by bending the aerosol-generating component against the grain orientation.

The aerosol-generating component 130 (including the one or more elongated apertures 130B and any other features thereof) may be as defined elsewhere herein.

There is also provided an article 100 for use as part of a non-combustible sol supply system, the article 100 comprising: an aerosol-generating component 130 as defined herein; and one or more of a reservoir for an aerosolizable material and an aerosol-generating chamber.

In some examples, the aerosol-generating component 130 is located at least partially in the aerosol-generating chamber.

In some examples, the reservoir is configured to provide the aerosolizable material to the aerosol-generating component 130.

There is also provided a non-combustible sol supply system comprising: an article comprising an aerosol-generating component 130 as defined herein; and means comprising one or more of a power source and a controller.

In some examples, the power source is configured to provide power to the aerosol-generating component 130 via the electrical connection 130C.

According to one aspect, there is provided an aerosol-generating component comprising: a plurality of elongated heating portions extending between the end portions, wherein elongated apertures are provided between adjacent heating portions, wherein at least one of the elongated apertures is tapered longitudinally. Without being bound by theory, it is believed that the tapering of the longitudinal apertures introduces a temperature gradient in the heating portions, as the central portion of each aperture is located farther from the edge of an adjacent one of the heating portions at the wider end than at the narrower end, and this temperature gradient helps drive and distribute the aerosolizable material along the heating portions. This provides more efficient heating of the aerosolizable material, reduces the amount of "static" aerosolizable material on the aerosol-generating component, and reduces the "pop" sound that may occur when heating the static aerosolizable material.

This aspect is best shown in fig. 5, where in fig. 5 the aerosol-generating component 130 comprises a plurality of elongate heating portions 130E extending between end portions 130E (not all heating portions 130E are labeled for clarity). An elongated aperture 130B (also referred to herein as a slotted aperture) is disposed between adjacent heating portions 130E. At least one of the elongated apertures 130B is tapered longitudinally (i.e., along the length of the aperture 130B). In use, the aerosolizable material is distributed along the elongate aperture 130B in a direction that increases the taper. In this example, the heating portions 130E are arranged side by side.

A plurality of elongated apertures 130B that taper longitudinally may be provided in the aerosol-generating component 130. Each elongated aperture 130B may be disposed between a respective pair of adjacent heating portions 130E. At least two adjacent elongated apertures 130B may taper in opposite directions. For example, where there are multiple elongated apertures 130B, the elongated apertures 130B may taper in alternating opposite directions. This may help provide a more even distribution of the aerosolizable material over the heated portion 130E and thereby improve aerosol generation.

The at least one elongated heating portion 130E may have a substantially constant cross-section, wherein the cross-section may be orthogonal to the length of the heating portion 130E.

At least one of the elongated apertures 130B may be enclosed. This is particularly advantageous for achieving movement of the aerosolizable material through the surrounding elongated open-cell structure (e.g., by capillary forces between adjacent heating portions 130E surrounding the elongated open cells 130B), thereby providing uniform distribution of the aerosolizable material across the heating portions 130E, particularly at "hot spots" that may be located at the ends of the elongated open cells 130B. In some examples, the at least one elongated aperture 130B is enclosed within or by the periphery of the aerosol-generating component 130. For example, at least one elongated aperture 130 may be surrounded by adjacent heating portions 130E and opposing end portions 130F.

For example, at least one (or each) of the elongated apertures 130B may have a maximum width of at most 2.0mm, or at most 1.8mm, or at most 1.6mm, or at most 1.5mm, or at most 1.4mm, or at most 1.2mm, or at most 1.0 mm. For example, at least one (or each) of the elongated apertures 130B may have a minimum width of at least 0.1mm, or at least 0.2mm, or at least 0.3mm, or at least 0.4 mm. This may also help promote movement of the aerosolizable material (e.g., by capillary forces) along the opposite edges of the heated portion 130E.

In some examples, the aerosol-generating component 130 is composed of a single layer.

In some examples, the aerosol-generating component 130 is made of an electrically conductive material.

The aerosol-generating component 130 may comprise any other features as defined elsewhere herein.

There is also provided an article for use as part of a non-combustible sol supply system, the article comprising: an aerosol-generating component 130; and one or more of a reservoir for an aerosolizable material and an aerosol-forming chamber.

There is also provided a non-combustible sol supply system comprising: an article comprising an aerosol-generating component 130; and means comprising one or more of a power source and a controller.

According to an alternative aspect, there is provided an aerosol-generating component comprising: a plurality of elongated heating portions extending between the end portions; wherein an elongated aperture is provided between adjacent heating portions, wherein at least one of the heating portions tapers longitudinally. In use, the most tapered (i.e. thinnest) portion of the heating portion heats up to the operating temperature first (because it has the highest electrical resistance), and then the tapered progressively smaller portions of the heating portion heat up to the operating temperature (because they have a relatively low electrical resistance). This non-uniformity of heating along the heating portion causes a temperature gradient that may help drive and distribute the aerosolizable material along the heating portion. This provides more efficient heating of the aerosolizable material, reduces the amount of "static" aerosolizable material on the aerosol-generating component, and reduces the "pop" sound that may occur when heating the static aerosolizable material.

This aspect is best shown in fig. 6, where in fig. 6 the aerosol-generating component 130 comprises a plurality of elongate heating portions 130E (not all of which are labeled for clarity) extending between end portions 130F. An elongated aperture 130B (also referred to herein as slotted aperture 130B) is disposed between adjacent heating portions 130E. At least one of the heating portions 130E tapers longitudinally (i.e., along the length of the heating portion 130E). In this example, the heating portions 130E are arranged side by side.

In some examples, the plurality of elongated heating portions 130E may taper longitudinally.

A plurality of elongated apertures 130B may be provided in the aerosol-generating component. Each elongated aperture 130B may be disposed between a respective pair of adjacent heating portions 130E.

The at least one elongated heating aperture 130B may have a substantially constant width (see fig. 6).

At least two adjacent heating portions 130E may taper in opposite directions. For example, in the case where there are a plurality of heating portions 130E, the heating portions 130E may taper in alternately opposite directions. This may help provide a more uniform distribution of the aerosolizable material over the heated portion 130E.

At least one of the elongated apertures 130B may be enclosed. In some examples, the at least one elongated aperture 130B is enclosed within or by the periphery of the aerosol-generating component 130. For example, at least one elongated aperture 130B may be surrounded by adjacent heating portions 130E and opposing end portions 130F.

For example, at least one (or each) of the heating portions 130E may have a maximum width of at most 2.0mm, or at most 1.8mm, or at most 1.6mm, or at most 1.5mm, or at most 1.4mm, or at most 1.2mm, or at most 1.0 mm. For example, at least one (or each) of the heating portions 130E may have a minimum width of at least 0.1mm, or at least 0.2mm, or at least 0.3mm, or at least 0.4 mm. This may also help to promote movement of the aerosolizable material along the heated portion.

There is also provided an article for use as part of a non-combustible sol supply system, the article comprising: an aerosol-generating component 130 as defined herein; and one or more of a reservoir for an aerosolizable material and an aerosol-generating chamber.

The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided as representative examples of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that the 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 utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist essentially of, or consist of, suitable combinations of the disclosed elements, components, features, components, steps, means, etc. in addition to those specifically described herein. In addition, the present disclosure may include other inventions not presently claimed but which may be claimed in the future.

Claims

1. An aerosol generating component comprising: a plurality of elongated heating portions extending between a plurality of end portions, wherein elongated openings are provided between adjacent heating portions, wherein at least one of the elongated openings tapers longitudinally.

2 . The aerosol generating member according to claim 1 , wherein a plurality of longitudinally tapered elongated openings are provided in the aerosol generating member.

3. An aerosol generating component according to claim 2, wherein each of the elongated openings is disposed between a corresponding pair of adjacent heating portions.

4. An aerosol generating member according to claim 2 or 3, wherein at least two adjacent elongated openings taper in opposite directions.

5. An aerosol generating member according to any one of claims 1 to 4, wherein at least one elongated heating portion has a substantially constant cross-section, wherein the cross-section is orthogonal to the length of the at least one heating portion.

6. An aerosol generating member according to any one of claims 1 to 5, wherein at least one of the elongate openings is surrounded.

7. An aerosol generating member according to claim 6, wherein at least one of the elongated openings is surrounded by the adjacent heating portion and the opposing end portion.

8. An aerosol generating member according to any one of claims 1 to 7, wherein the or each elongate aperture has a minimum width of at least 0.1 mm and a maximum width of at most 2.0 mm.

9. An aerosol-generating member according to any one of claims 1 to 8, wherein the aerosol-generating member is substantially planar.

10. The aerosol generating member according to any one of claims 1 to 9, wherein the aerosol generating member is composed of a single layer.

11. An aerosol generating member according to any one of claims 1 to 10, wherein the aerosol generating member is made of an electrically conductive material.

12. An aerosol generating component comprising: a plurality of elongated heating portions extending between a plurality of end portions; wherein elongated openings are provided between adjacent said heating portions, wherein at least one of said heating portions tapers longitudinally.

13. An aerosol generating component according to claim 12, wherein a plurality of the elongate heating portions taper longitudinally.

14. An aerosol generating member according to claim 13, wherein at least two adjacent heating portions taper in opposite directions.

15. An aerosol generating member according to any one of claims 12 to 14, wherein at least one of the elongate openings is surrounded.

16. An aerosol generating member according to claim 15, wherein at least one of the elongate openings is surrounded by an adjacent the heating portion and an opposing the end portion.

17. An aerosol-generating member according to any one of claims 12 to 16, wherein at least one of the heating portions has a minimum width of at least 0.1 mm and a maximum width of at most 2.0 mm.

18. An aerosol-generating member according to any one of claims 12 to 17, wherein the aerosol-generating member is substantially planar.

19. An aerosol generating member according to any one of claims 12 to 18, wherein the aerosol generating member is composed of a single layer.

20. An aerosol-generating member according to any one of claims 12 to 19, wherein the aerosol-generating member is made of an electrically conductive material.

21. An article for use as part of a non-flammable aerosol supply system, the article comprising: an aerosol generating component according to any one of claims 1 to 20; and one or more of a reservoir for an aerosolizable material and an aerosol generating chamber.

22. The article of claim 21, wherein the aerosol generating component is at least partially located in the aerosol generating chamber.

23. An article according to claim 21 or 22, wherein the reservoir is configured to provide aerosolizable material to the aerosol generating component.

24. The article of any one of claims 21 to 23, wherein the reservoir is configured to hold a liquid aerosolizable material.

25. An article according to any one of claims 21 to 24, wherein the aerosol generating component is biased against an aerosol generating material transport component.

26. A non-flammable aerosol supply system comprising: an article comprising an aerosol generating component according to any one of claims 1 to 20; and a device comprising one or more of a power source and a controller.