EP4646947A1

EP4646947A1 - Aerosol generator

Info

Publication number: EP4646947A1
Application number: EP24174663.5A
Authority: EP
Inventors: Mark Potter; Andrew Denley; Ryan HEPBURN; Tom Woodman
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-05-07
Filing date: 2024-05-07
Publication date: 2025-11-12
Also published as: WO2025233371A1

Abstract

An aerosol generator (304) of an article for an aerosol provision device comprising: a resistive heating layer (340) having a first side (340a) and a second side (340b), the resistive heating layer comprising an electrically conductive material, a layer of aerosol generating material (330) on the first side of the resistive heating layer and at least one heating element (342) on the second side of the resistive heating layer. Each heating element extends from an electrical connection of a first type to an electrical connection of a second type.

Description

Technical Field

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

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.
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.

Summary

The scope of protection sought for various embodiments of the invention is set out by the independent claims. The embodiments and features, if any, described in this specification that do not fall under the scope of the independent claims are to be interpreted as examples useful for understanding various embodiments of the invention.
According to an aspect, there is provided a method of forming an aerosol generator of an article for an aerosol provision device, the method comprising:

a) providing a resistive heating layer having a first side and a second side, the resistive heating layer comprising an electrically conductive material;
b) providing a layer of aerosol generating material on the first side of the resistive heating layer;
c) forming at least one heating element on the second side of the resistive heating layer wherein the or each heating element extends from an electrical connection of a first type to an electrical connection of a second type.

The first side may be referred to as the aerosol generating side. The second side may be referred to as the resistive track side.
Step c) may comprise forming the or each resistive heating element comprises by at least one of: cutting the resistive heating layer; chemically etching the resistive heating layer; forming or pressing the resistive heating layer in the substrate; and printing the resistive heating layer.
Step b) may comprise: coating the first side of the resistive heating layer with a slurry of aerosol generating material; setting the slurry; drying to form the layer of aerosol generating material.
Step b) may comprise: casting a slurry of the aerosol generating material onto a mesh structure; setting the slurry; drying to form the layer of aerosol generating material as an aerosol generated coated mesh; assembling the layer to the first side of the resistive heating layer.
The aerosol generating material may at least partially coat the mesh structure, such that the mesh is partially embedded within the aerosol generating material.
The aerosol generating material may fully coat the mesh structure, such that the mesh is embedded within the aerosol generating material.
The aerosol generating material may coat the mesh structure, such that openings are provided in the aerosol generating layer.
The mesh structure may be an organic mesh. The mesh structure may be an inorganic mesh. The mesh structure may be a high temp mesh material. The mesh structure may be a fine mesh sheet of PEEK. The mesh structure may be a woven ceramic fibre mesh.
Step b) may comprise: casting a slurry of aerosol generating material onto a casting surface; setting the slurry to form a thin film of aerosol generating material; peeling the thin film of aerosol generating material from the casting surface to form the layer of aerosol generating material; assembling the layer of aerosol generating material to the first side of the resistive heating layer.
Step b) may be performed before step c). Step c) may be performed before step c). Steps b) and c) may be performed at least partially simultaneously.
Assembling the layer of aerosol generating material to the first side of the resistive heating layer may comprise placing the layer of aerosol generating material onto the first side of the resistive heating layer, and applying pressure to the aerosol generating material.
Assembling the layer of aerosol generating material to the first side of the resistive heating layer may comprise: applying bonding material to a first side layer of aerosol generating material; placing the first side on the first side of the resistive heating layer; and setting the bonding material.
The bonding material may be a slurry of the aerosol generating material. The bonding material may be a slurry of a second aerosol generating material.
The method may further comprise step d) applying a support layer to the second side of the resistive heating layer.
Step c) may comprise providing a plurality of resistive heating elements are provided on the resistive heating layer.
The method may further comprise forming a plurality of surface features on the resistive heating layer.
The plurality of surface features may comprise a plurality of perforations.
The method may further comprise a step of cropping around each of the plurality of resistive heating elements to form individual cropped aerosol generators (also referred to as cropped resistive heating elements).
The method may be implemented on a production line.
The method may comprise providing a continuous band of the resistive heating layer moving along a production line. The method may comprise applying the aerosol generating layer to the resistive heating layer at a first point on the production line. The method may comprise forming at least one heating element at a second point along the production line. The method may further comprise cropping the resistive heating layer at a third point along the production line to form individual, cropped aerosol generators (also referred to as cropped heating elements).
The method may further comprise applying a support layer on the second side after formation of a heating element. The method may further comprise applying a support layer on the second side after formation of a heating element and before cropping. The method may further comprise applying a support layer to each individual cropped aerosol generator.
According to another aspect there is provided a method of forming an aerosol generator assembly for an article for an aerosol provision device, the method comprising forming a plurality of cropped aerosol generators in accordance with any method described above and assembling the plurality of cropped aerosol generators onto a base.
According to a further aspect there is provided an article for use with an aerosol generating device comprising the aerosol generator assembly as described above.
According to another aspect there is provided an aerosol generator manufactured in accordance with any method described above.
According to another aspect there is provided an aerosol generator of an article for an aerosol provision device comprising

a resistive heating layer having a first side and a second side, the resistive heating layer comprising an electrically conductive material
a layer of aerosol generating material on the first side of the resistive heating layer
at least one heating element on the second side of the resistive heating layer wherein
wherein the heating element extends from an electrical connection of a first type to an electrical connection of a second type.

The heating element may provide an electrically conductive path for resistive heating of a portion of said aerosol generating material to generate an aerosol at the respective portion of the layer of aerosol generating material.
The resistive heating layer may be a conductive metallic material. The resistive heating layer may be aluminium. The resistive heating layer may be a foil.
The resistive heating layer comprises a plurality of surface features. The plurality of surface features may comprise a plurality of perforations. The plurality of surface features may comprise at least one of a plurality of indents and a plurality of protrusions.
The layer of aerosol generating material may comprise a mesh structure.
The mesh structure may be an organic mesh. The mesh structure may be an inorganic mesh. The mesh structure may be a high temp mesh material. The mesh structure may be a fine mesh sheet of PEEK. The mesh structure may be a woven ceramic fibre mesh.
The aerosol generator may comprise a plurality of resistive heating elements. Each resistive heating element may be configured to heat a respective portion of the aerosol generating material to generate an aerosol, the aerosol generating layer being on the resistive heating layer, wherein each of the plurality of resistive heating elements extends between an electrical contact of a first type and an electrical contact of a second type.
The electrical contacts may be configured to enable an electric current to be individually provided to each of the plurality of heating elements.
The aerosol generator may comprise a plurality of electrical contacts of the first type. Each of the plurality of resistive heating elements may have a separate electrical contact of the first type. The electrical contacts may comprise a single electrical contact of the second type. The single contact of the second type may be shared between each of the plurality of heating elements. The aerosol generator may comprise a plurality of electrical contacts of the second type, wherein each of the heating elements has a separate electrical contact of the second type.
The resistive heating layer may define the electrical contacts of the first type and the electrical contact(s) of the second type.
The electrical contact of the first type may be configured to electrically connect with a device electrical connector.
The electrical contact of the first type may comprise an exposed contact area.
The generator may comprise an electrical track of a second type extending from the plurality of heating elements and comprising the electrical contact of the second type.
The electrical contact of the second type may be configured to electrically connect with a device electrical connector. The electrical contact of the second type may comprise an exposed contact area.
According to another aspect there is provided an article for use in an aerosol provision device comprising an aerosol generator as described above.
The article may comprise a plurality of aerosol generators. Each of the plurality of aerosol generators may comprise a single resistive heating element. Each of the plurality of aerosol generators may comprise two or more resistive heating elements.
According to another aspect there is provided an aerosol provision system comprising an aerosol provision device and an article as described above.
In an embodiment of any of the above, the plurality of surface features comprises a plurality of perforations. In an embodiment of any of the above, the plurality of surface features comprises at least one of a plurality of indents and a plurality of protrusions.
In an embodiment of any of the above, at least some of the surface features are formed along the electrically conductive path.
In an embodiment of any of the above, the plurality of surface features are configured to at least partially determine the electrical resistance along the electrically conductive path.
In an embodiment of any of the above, comprising an array of the surface features. In an embodiment of any of the above, the surface features are regularly spaced in the array of surface features.
In an embodiment of any of the above, the aerosol generating layer comprises a plurality of aerosol generating layer perforations.
In an embodiment of any of the above, the plurality of surface features of the resistive heating layer are aligned with the plurality of aerosol generating layer perforations.
In an embodiment of any of the above, the aerosol generating layer is free from perforations.
In an embodiment of any of the above, each 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.
In an embodiment of any of the above, the at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact is a non-linear path.
In an embodiment of any of the above, the at least a portion of an electrically conductive path between the first type of electrical contact and the second type of electrical contact is a meandering path.
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 aerosol generator comprises a support configured to support the resistive heating layer.
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.
In an embodiment of any of the above, the support comprises at least one of paper and card.
In an embodiment of any of the above, the aerosol generating layer is in direct 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.
In an embodiment of any of the above, the resistive heating layer and the support layer define a substrate.
In an embodiment of any of the above, the aerosol generator comprises a laminate comprising the resistive heating layer and the support layer.
In an embodiment of any of the above, the laminate comprises the aerosol generating layer.
In an embodiment of any of the above, the support layer comprises a card layer.
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.
In an embodiment of any of the above, the support defines an exposed contact area of the first type of electrical contact.
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.
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 layer is a discontinuous aerosol generating layer.
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.
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.
In an embodiment of any of the above, the aerosol generating layer comprises at least one of dots, strips and patches.
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.
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.
In an embodiment of any of the above, the plurality of heating elements comprises a single row of resistive heating elements.
In an embodiment of any of the above, the array of heating elements are arranged in a row parallel to a longitudinal axis.
In an embodiment of any of the above, the array of heating elements are arranged in a row perpendicular to a longitudinal axis
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.
In an embodiment of any of the above, wherein the aerosol generating layer comprises a film or gel layer comprising the aerosol generating material.
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 first type of electrical contact.
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.
In an embodiment of any of the above, wherein the aerosol generator comprises a single second type of electrical contact.
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, wherein the resistive heating element is formed by at least one of: cutting the resistive heating layer; chemically etching the resistive heating layer; forming or pressing the resistive heating layer in the substrate; and printing the resistive heating layer.
In an embodiment of any of the above, wherein the resistive heating layer is in the form of a foil.
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.
According to an aspect, there is provided an aerosol provision system comprising an aerosol generator or an article for an aerosol provision device of any of the above, and an aerosol provision device of any of the above.

Brief Description of the Drawings

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;
Figure 2 is a schematic perspective view of an article comprising aerosol generating material of the aerosol provision system of Figure 1;
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;
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 2, with an aerosol generator shown inverted from an assembled orientation and in a spaced relationship with other components;
Figures 7a and 7b are schematic cross-sectional views aerosol generators such as the aerosol generator shown in Figure 3;Figures 7c and 7d show plan views of resistive heating layers;
Figure 8 is a schematic plan view of a resistive heating element of the aerosol generator of Figure 3;
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;
Figures 10a to 10d are flow charts showing methods of forming an aerosol generator, such as the aerosol generator of Figure 3;
Figure 11 is an exploded perspective view of an aerosol generator being formed;
Figures 12 and 13 are a schematic perspective views of a resistive heating layer of an aerosol generator being formed;
Figures 14 and 15 are a schematic plan view of a heating element of an aerosol generator;
Figure 16 is a schematic perspective view of part of an aerosol generator of the article of Figure 2;
Figure 17 is a schematic perspective view of a device connector of an aerosol provision device of the aerosol provision system of Figure 1;
Figure 18 is a schematic side view of the aerosol provision system of Figure 1;
Figure 19 shows a flow chart of another method of forming an aerosol generator
Figures 20a to 20c show further details of the method of forming an aerosol generator of Figures 10;
Figures 21a and 21b are schematic cross-sectional views other aerosol generators;
Figures 21c and 21c are views of an aerosol generator assembly;
Figures 22a to 22c shows a plan view of an aerosol generator assembly 305 formed from two aerosol generators 304 of Figure 21b;
Figures 23 and 24 show a method for forming an aerosol generator assembly 305;
Figure 25 shows another method for forming aerosol generator assemblies 305; and
Figure 26 is a flow chart showing a method of operating an aerosol generator, such as the aerosol generator of Figure 3.

Detailed Description

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.
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.
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.
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.
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.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
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.
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.
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.
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.
In some embodiments, the substance to be delivered comprises an active substance (sometimes referred to herein as an active compound).
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.
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.
The aerosol-generating material may comprise or be in the form of an aerosol-generating 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.
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.
The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material.
The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating 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.
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.
The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.
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 aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water.
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.
The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
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.
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.
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.
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 aerosol-generating material storage area, an aerosol-generating material 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, for example, comprise a material heatable by electrical conduction.
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.
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.
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 describe in detail below.
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.
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.
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.
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 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.
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.
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.
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.
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.
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.
In the use of the aerosol provision system 100, air is drawn into an air inlet 314 of the article 300, as indicated by arrow 316. The air inlet 314 is in a distal end of the article 300. In embodiments, the air inlet 314 may have a different configuration, for example in the side. 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 10.
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.
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.
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.
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 Figure 6) 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 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.
The air inlet 314 comprises an opening 315. The opening 315 is formed in 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.
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.
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.
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 304, 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 other embodiments, one or more of the first and second aerosol generators 304 and the body 324 has a greater length and/or width. In other 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.
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. 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 Figures 7a and 7b. The aerosol generators 304 are example implementations of the aerosol generator 304 of the aerosol provision system 100 described above.
In Figure 7a, 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 has a first side 340a and a second side 340b. The resistive heating layer 340, in embodiments, is formed as an electrically conductive layer. The aerosol generating layer 330 is provided on the first side 340a of 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, for example a coating layer on the resistive heating later 340 on the first side 340a provided between the resistive heating layer and the aerosol generating layer 340. As described in detail below, the resistive heating layer 340 comprises a plurality of resistive heating elements 342 provided on the second side 340b, 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.
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 or graphite. The resistive heating layer 340 is in the form of a foil, for example an aluminium foil.
Figure 7b, shows an aerosol generator 304 having an aerosol generating layer 330, a resistive heating layer and additionally 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 7b, in the aerosol generator 304, the resistive heating layer 340 is sandwiched between the support 350 and the aerosol generating layer 330.
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.
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.
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.
Figure 7c shows an electrically conductive layer, indicated generally by the reference numeral 340, in accordance with an example embodiment. The electrically conductive layer 340 comprises a heating element 342, a first electrical connection 346 and a second electrical connection 347. In some example embodiments, the first electrical connection 346 provides a positive connection and the second electrical connection 347 provides a negative connection such that electrical current flows between the electrical connections through the heating element 342. As shown in Figure 4, the heating element 342 comprises a plurality of perforations (including perforations 348a 348b, 348c etc.).
The plurality of perforations act as surface features. In embodiments, the surface features comprise at least one of protrusions, recesses, indentations, depressions, holes, perforations, gaps, etc. Surface features may be a localised distortion or formation of a layer such that at least one of the volume of material across the thickness and/or width of the heating element at a particular position or positions along the heating element differs from the volume of material across the thickness and/or width of the heating element at another particular position or positions along the heating element. The embodiments described herein describe a plurality of perforations for exemplary purposes, and the skilled person would understand that the plurality of protrusions may be any surface feature.
The electrical resistance of the heating element 342 may be dependent on the nature of the perforations in the conductive layer (e.g. the size, quantity and distribution of the perforations). Thus, the perforated conductive layer may have a higher electrical resistance when compared with a straight, unperforated, path between the first and second electrical connectors.
The electrically conductive layer 340 can be used as the electrically conductive layer 340 of the aerosol generator as described here (or some similar aerosol generator) such that the electrically conductive path of the heating element 342 can be used for resistive heating of a portion of an aerosolisable material to generate an aerosol.
Figure 7d shows an electrically conductive layer, indicated generally by the reference numeral 40, in accordance with an example embodiment. The electrically conductive layer 340 comprises a first heating element 342a, a second heating element 342b, first electrical connections 346a and 346b, and a second electrical connection 347. In some example embodiments, the first electrical connections 346a, 346b each provide a positive connection and the second electrical connection 56 provides a negative connection such that electrical current flows between the electrical connections through the heating elements 342a and 342b.
The number of electrical connections, which may also be referred to as electrical contacts, may vary. As such, each heating element 342a, 342b extends between a discrete first type of electrical contact and a common second type of electrical contact.
As shown in FIG. 7d, the heating elements 342a and 342b comprises a plurality of perforations (including perforations 348 etc.). The two heating elements are formed by a cut 349 in the electrically conductive layer that separates the first and second heating elements. The cut 349 may be generated by laser cutting or some similar process (as discussed further below).
In other embodiments, the resistive heating layer comprises a plurality of surface features. In embodiments, at least some of the plurality of perforations are formed along the electrically conductive path. The plurality perforations may affect the electrical properties of the electrically conductive path. The plurality of surface features in embodiments are configured to at least partially determine the electrical resistance along the electrically conductive path. In embodiments, the plurality of surface features in embodiments are configured to be free from or minimise an effect on the electrical resistance along the electrically conductive path.
The perforations may be arranged in the heating elements in a variety of configurations. The heating elements may comprise an array of perforations. The heating elements may comprise a plurality of arrays of perforations. The perforations may be regularly spaced in the array of perforations. In various embodiments, many varieties of distributions of the perforations are envisaged. The perforations may be distributed in any one of parallel rows, parallel columns, regularly, irregularly, randomly, etc.
Figure 8 shows one of the resistive heating elements 342. The resistive heating layer 340 comprises a plurality of resistive heating elements 342 formed on the second side 340b of the resistive heating layer 340. In embodiments, the resistive heating layer 340 comprises a single resistive heating element 342.
The plurality of heating elements 342 may be formed in an array 344 as shown in Figure 9. Other configurations are envisaged.
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.
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.
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.
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.
As discussed in detail below, the conducting path of the resistive heating element 342 in embodiments is created by defining at least one electrically conductive barrier 346 in the resistive heating layer 340. In embodiments, the electrically conductive barrier 346 is formed by cutting electrically conductive 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 electrically conductive element 342 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 at least one electrically conductive barrier 346 defines the first and second types of electrical track 361, 366.
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 × 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 µOhmcm, 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.
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.
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.
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.
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.
Figures 10a to 10d are a flow charts showing part of a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 400, in accordance with example embodiments.
In Figure 10a, the method or algorithm 400 starts at operation 410, in which a resistive heating layer 340 is provided.
In operation 420, the aerosol generating layer 330 is provided on the first side 340a of the resistive heating layer 340.
In operation 430, where a resistive heating layer 340 is formed into one or more heating elements 342 provided on the second side 340b of the resistive heating layer (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.
It has been found that providing the layer of aerosol generating material on the opposite side to the heater elements 342 allows gases etc to escape during the step of forming the resistive heating elements, for example during a laser cutting process. This reduces the delamination of the aerosol generating material from the heater material layer.
Figure 10b shows a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 400', in accordance with another example embodiment.
In the method of 10b, the heating elements 342 are provided on the second side 340b of the resistive heating layer (step 430) and subsequently, the layer of aerosol generating material 330 is provided on the first side 340a (step 420).
The method of Figure 10c includes an additional step 415 of forming a plurality of surface features on the resistive heating layer.
It will be appreciated that in other embodiments, step 415 can be performed at a different stage in the method, for example as shown in Figure 10d, method 400‴ shows step 415 is performed after formation of the heating elements and provision of the layer of aerosol generating material.
In embodiments, the surface features comprise at least one of protrusions, recesses, indentations, depressions, holes, perforations, gaps, etc. Surface features may be a localised distortion or formation of a layer such that at least one of the volume of material across the thickness and/or width of the heating element at a particular position or positions along the heating element differs from the volume of material across the thickness and/or width of the heating element at another particular position or positions along the heating element. The embodiments described herein describe a plurality of perforations for exemplary purposes, and the skilled person would understand that the plurality of protrusions may be any surface feature.
In embodiments, at least some of the plurality of perforations are formed along the electrically conductive path. The plurality perforations may affect the electrical properties of the electrically conductive path. The plurality of surface features in embodiments are configured to at least partially determine the electrical resistance along the electrically conductive path. In embodiments, the plurality of surface features in embodiments are configured to be free from or minimise an effect on the electrical resistance along the electrically conductive path.
In other embodiments, the methods of Figures 10a to d include an additional step of providing a support layer on the second side 340b of the of the resistive heating layer 340. It will be appreciated that this is done after formation of the heater element(s). Figure 11 shows the aerosol generator 304 being formed in accordance with an embodiment corresponding to Figure 10b. The resistive heating layer is provided with heating elements on the second side 343. The aerosol generating material 302 is formed on the first side 342 of the resistive heating layer 340 by depositing aerosol generating material, for example by spraying, painting, dispensing or in some other way, indicated by arrow 420
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. In the methods of Figures 10a and 10d, according to one embodiment, step 430 is achieved by cutting the second side of the resistive heating layer to form the paths.
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.
In an alternative embodiment, in operation 340, the one or more of the resistive heating elements are formed in the resistive heating layer by chemically etching the resistive heating layer.
In another embodiment, in step 430 the one or more heating elements are formed, at least in part, by printing a resistive heating layer.
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.
Figure 13 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.
In the embodiment of Figure 13, the paths cut are linear paths, extending along the length of the electrically conductive layer 120.
Figure 14 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.
Figure 15 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 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 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.
Figure 16 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.
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.
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.
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.
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.
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.
The aerosol generator 304 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 17 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.
Figure 18 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.
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.
Figure 19a shows an example embodiment for method step 420 of Figure 10. In this embodiment, in step 422 the first side of the resistive heating layer 340 is coated with a slurry of aerosol generating material. The slurry can be applied in a continuous layer or in a plurality of discrete portions. In step 424, the slurry is set and then in step 426 it is dried to form the layer of aerosol generating material 330. It will be understood that in the case where a plurality of discrete portions of the slurry are applied in step 422, the layer of aerosol generating material formed will be a discontinuous layer.
Figure 20a shows another example embodiment for method step 420 of Figure 10. In this embodiment, step 422 comprises casting a slurry of the aerosol generating material 330 onto a mesh structure 335 (shown in Figure 20b). The slurry can be applied in a continuous layer or in a plurality of discrete portions. In step 424 the slurry is set and then in step 426 it is dried to form the layer of aerosol generating material 330 as an aerosol generated coated mesh. In step 428, the as an aerosol generated coated mesh is assembled to the first side of the resistive heating layer 340. This is shown in Figure 20c, in which a bonding layer 338 is provided between the layer of aerosol generating material 330 and the resistive heating layer 340.
Figure 21a shows a cross-sectional view of the aerosol generator 304 the aerosol generating layer 330 comprising the mesh structure 335 and the resistive heating layer 340. Figure 21b shows another embodiment of an aerosol generator 304 further including a support layer 350.
The mesh structure 335 can be any suitable type of mesh. In some embodiments it is an organic mesh. In some embodiments it is an inorganic mesh. The mesh may be a high temp mesh material. The mesh structure may be a fine mesh sheet of PEEK or a woven ceramic fibre mesh.
The mesh provides structural integrity to the aerosol generating material layer, allowing it to be more easily handled and processed.
Figures 22a to 22c shows a plan view of an aerosol generator assembly 305 formed from two aerosol generators 304 of Figure 21b.
Each resistive heating layer 340 comprises the resistive heating elements 342 (not visible), 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.
Figures 23 show a method for forming an aerosol generator assembly 305 which can be incorporated into an article for use in aerosol generating device (for example the articles and or devices described earlier). The aerosol generator assembly 305 comprises multiple individual aerosol generators on a base, and the component assembly process is schematically represented in Figure 24.
Steps 410, 420 and 430 are the same shown in Figure 10a, and as described above. In step 430, a substrate layer is applied to the second side 340b of the resistive heating layer 340. The support layer provides structure and rigidity.
In step 450, the heating element is cropped to form a plurality of cropped heating elements, and in step 460 the plurality of cropped heating elements (also referred to as an aerosol generator assembly) are applied to a base 301 to form the aerosol generator assembly 305.
It will be appreciated that the aerosol generator assembly can be incorporated into an article for use in an aerosol generating device, such as described above.
Figure 25 shows an alternative implementation of the method for forming aerosol generators. This method involves a production line. In step 420 aerosol generating material is applied to a first side 340a of a moving band of resistive heating layer 340 at a first point on the production line. The aerosol generating material may be provided as a continuous film which is bonded to the resistive heating layer. Alternatively, the aerosol generating material may be provided as a slurry which is cast onto the resistive heating layer, set and dried, as described the method of Figure 19.
In other embodiments, assembling the layer of aerosol generating material to the first side of the resistive heating layer comprises placing the layer of aerosol generating material onto the first side of the resistive heating layer, and applying pressure to the aerosol generating material.
In step 430 the resistive heating elements 42 are provided on the second side 340b at a second point on the production line. The heating elements can be provided using a laser cutter 408 (or other suitable machinery).
In step 440, the individual heating elements are cropped at a third point on the production, using any suitable cutting tool 409.
These cropped heating elements can be assembled onto a base to form an aerosol generator assembly. As described above, the consumable substrate can be incorporated into an article for use in an aerosol provision device
In another embodiment, a continuous band of mesh can be provided on the first side of the resistive heater layer, onto which the aerosol generating material is applied.
In another embodiment, a substrate layer is provided on the second side of the resistive heating layer after formation of the heating elements. The substrate layer may be provided before or after the cutting operation.
Figure 26 is a flow chart showing method of operation or an algorithm, indicated generally by the reference numeral 500, in accordance with an example embodiment. The method or algorithm 500 may, for example, be implemented using any of the aerosol generators described herein. The method or algorithm 500 is initiated when an instruction to activate heating is received in an instance of operation 510. In response to the instruction to activate heating, a determination is made (in operation 512) regarding whether a heating element is available. As discussed above, a plurality of heating elements may be provided. The operation 512 may involve determination which of the heating elements have been used and/or the corresponding available aerosol generating material used up.
If a heating element is available, the algorithm moves to operation 514, 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 514 is complete, the algorithm terminates at operation 516. If, at operation 512, 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 516. This may mean that a consumable part being used to implement the algorithm 500 needs to be replaced.
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

1. A method of forming an aerosol generator of an article for an aerosol provision device, the method comprising:

a) providing a resistive heating layer having a first side and a second side, the resistive heating layer comprising an electrically conductive material;

b) providing a layer of aerosol generating material on the first side of the resistive heating layer;

c) forming at least one heating element on the second side of the resistive heating layer wherein the or each heating element extends from an electrical connection of a first type to an electrical connection of a second type.

2. The method of claim 1 wherein step c) forming the or each resistive heating element comprises by at least one of: cutting the resistive heating layer; chemically etching the resistive heating layer; forming or pressing the resistive heating layer in the substrate; and printing the resistive heating layer.

3. The method of claim 1 or claim 2, wherein step b) comprises:

coating the first side of the resistive heating layer with a slurry of aerosol generating material;

setting the slurry;

drying to form the layer of aerosol generating material.

4. The method of any of claims 1 to 3, wherein step b) comprises:

casting a slurry of the aerosol generating material onto a mesh structure;

setting the slurry;

drying to form the layer of aerosol generating material as an aerosol generated coated mesh;

assembling the layer to the first side of the resistive heating layer.

5. The method of any of claims 1 to 3, wherein step b) comprises:

casting a slurry of aerosol generating material onto a casting surface;

setting the slurry to form a thin film of aerosol generating material;

peeling the thin film of aerosol generating material from the casting surface to form the layer of aerosol generating material;

assembling the layer of aerosol generating material to the first side of the resistive heating layer.

7. The method of claim 5 or claim 6, wherein assembling the layer of aerosol generating material to the first side of the resistive heating layer comprises:

applying bonding material to a first side layer of aerosol generating material;

placing the first side on the first side of the resistive heating layer; and

setting the bonding material.

8. The method of any of claims 1 to 7, further comprising
d) applying a support layer to the second side of the resistive heating layer.

9. The method of any of claims 1 to 8, wherein in step c) a plurality of resistive heating elements are provided on the resistive heating layer.

10. An aerosol generator manufactured according to any of claims 1 to 9.

11. An aerosol generator of an article for an aerosol provision device comprising

a resistive heating layer having a first side and a second side, the resistive heating layer comprising an electrically conductive material

a layer of aerosol generating material on the first side of the resistive heating layer

at least one heating element on the second side of the resistive heating layer

wherein the heating element provides an electrically conductive path for resistive heating of a portion of said aerosol generating material to generate an aerosol at the respective portion of the layer of aerosol generating material and

wherein the heating element extends from an electrical connection of a first type to an electrical connection of a second type.

12. The aerosol generator according to claim 10 or claim 11, wherein the layer of aerosol generating material comprises a mesh structure.

13. The aerosol generator according to any of claims 10 to 12, comprising a plurality of resistive heating elements, each resistive heating element being configured to heat a respective portion of the aerosol generating material to generate an aerosol, the aerosol generating layer being on the resistive heating layer, wherein each of the plurality of resistive heating elements extends between an electrical contact of a first type and an electrical contact of a second type.

14. An article for use in an aerosol provision device comprising an aerosol generator according to any of claims 10 to 13.

15. An aerosol provision system comprising an aerosol provision device and an article as described in claim 14.