Note: Descriptions are shown in the official language in which they were submitted.
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AEROSOL PROVISION SYSTEM
Field
The present invention relates to a provision system, in particular to a non-
combustible
aerosol provision system and to components of said aerosol provision system.
Background
Non-combustible aerosol provision systems which generate an aerosol for
inhalation by
a user are known in the art. Such systems typically comprise an aerosol
generating component
which is capable of converting an aerosolisable material into an aerosol. In
some instances, the
aerosol generated is a condensation aerosol whereby an aerosolisable material
is first
vaporised and then allowed to condense into an aerosol. In other instances,
the aerosol
generated is an aerosol which results from the atomisation of the
aerosolisable material. Such
atomisation may be brought about mechanically, e.g. by subjecting the
aerosolisable material to
vibrations so as to form small particles of material that are entrained in
airflow. Alternatively,
such atomisation may be brought about electrostatically, or in other ways,
such as by using
pressure etc.
Since such aerosol provision systems are intended to generate an aerosol which
is to be
inhaled by a user, consideration should be given to the characteristics of the
aerosol produced.
These characteristics can include the size of the particles of the aerosol,
the total amount of the
aerosol produced, etc.
Where the aerosol provision system is used to simulate a smoking experience,
e.g. as
an e-cigarette or similar product, control of these various characteristics is
especially important
since the user may expect a specific sensorial experience to result from the
use of the system.
It would be desirable to provide aerosol delivery systems which have improved
control of
these characteristics.
Summary
According to a first aspect of the present disclosure, there is provided an
aerosol
generating component comprising: at least one elongate slit, wherein the width
of one, more, or
each elongate slit is up to 0.3 mm.
The width of one, more, or each elongate slit is greater than 0 mm. In some
examples, the
width of one, more, or each elongate slit is up to 0.25 mm. In some examples,
the width of one,
more, or each elongate slit is at least 0.05 mm, or at least 0.1 mm, or at
least 0.15 mm. In some
examples, the width of one, more, or each elongate slit is between 0.05 mm and
about 0.3 mm,
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or between 0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm, or between 0.15
mm and 0.25
mm. In some examples, the width of one, more, or each elongate slit is about
0.2 mm.
In some examples, the aerosol generating component is substantially planar.
In some examples, the aerosol generating component comprises multiple elongate
slits
as defined herein.
In some examples, one, more, or each elongate slit comprises multiple elongate
slit
sections.
In some examples, one, more, or each elongate slit section is substantially
straight.
In some examples, one, more, or each elongate slit section is curved. In some
examples,
the curvature is in the plane of the substantially planar aerosol generating
component.
In some examples, at least two of the elongate slit sections are non-parallel
with respect
to each other.
In some examples, at least two of the elongate slit sections are obliquely
angled with
respect to each other.
In some examples, one, more or each elongate slit is open at the periphery of
the aerosol
generating component.
In some examples, one, more or each elongate slit is enclosed by the periphery
of the
aerosol generating component.
In some examples, the aerosol generating component comprises: an aerosolisable
material feed section configured to receive aerosolisable material; and an
aerosolisation section
configured to aerosolise aerosolisable material.
The aerosolisation section may be characterized as that section which
experiences a
temperature of within 50%, or within 60%, or within 70%, or within 80% or
within 90% of the
maximum temperature reached by the aerosol generating component.
In some examples, one, more, or each elongate slit is provided in the
aerosolisation
section.
In some examples, one, more, or each elongate slit does not extend into the
aerosolisable
material feed section. In other words, the one, more, or each elongate slit
may be confined to the
aerosolisation section.
In some examples, one, more, or each elongate slit is connected to an elongate
slot.
In some examples, one, more, or each elongate slot is provided in the
aerosolisation
section.
In some examples, one, more, or each elongate slot does not extend into the
aerosolisable
material feed section.
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In some examples, one, more, or each elongate slit is provided in the
aerosolisable
material feed section.
In some examples, the width of one, more, or each elongate slot is greater
than 0.3 mm,
or at least 0.35 mm. In some examples, the width of one, more, or each
elongate slot is up to 3
mm, or up to 2.5 mm, or up to 2 mm, or up to 1.5 mm, or up to 1 mm, or up to
0.8 mm, or up to
0.7 mm, or up to 0.6 mm, or up to 0.55 mm. In some examples, the width of one,
more, or each
elongate slot is greater than 0.3 mm and up to 1 mm, or greater than 0.3 mm
and up to 0.8 mm,
or greater than 0.3 mm and up to 0.6 mm, or greater than 0.3 mm and up to 0.55
mm. In some
examples, the width of one, more, or each elongate slot is between 0.25 mm and
1 mm, or
between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or between 0.35 mm
and 0.55
mm, or between 0.4 mm and 0.5 mm.
In some examples, the aerosol generating component comprises one or more
electrical
connectors.
In some examples, the aerosol generating component is formed of a porous
material.
In some examples, the aerosol generating component is formed of an
electrically
conductive material. In some examples, the aerosol generating component is
formed of a single
layer.
In some examples, the aerosol generating component is formed from a woven or
weave
structure, mesh structure, fabric structure, open-pored fiber structure, open-
pored sintered
structure, open-pored foam or open-pored deposition structure.
In one aspect of the present disclosure, there is provided an article for use
as part of a
non-combustible aerosol provision system, the article comprising: an aerosol
generating
component according to a previous aspect of the present disclosure; and one or
more of an
aerosol forming chamber and a reservoir for aerosolisable material.
In one aspect of the present disclosure, there is provided a non-combustible
aerosol
provision system comprising: an article according to a previous aspect of the
present disclosure;
and a device comprising one or more of a power source and a controller.
In one aspect of the present disclosure, there is provided an aerosol
generating
component comprising at least one curved, elongate aperture.
In some examples, the aerosol generating component comprises multiple curved,
elongate apertures as defined herein.
In some examples, one, more, or each curved, elongate aperture increases in
curvature
from one end of the aperture to the other end of the aperture.
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In some examples, one, more, or each curved, elongate aperture is curved along
at least
part of its length. The part of the aperture that is curved may be provided
towards the periphery
of the aerosol generating component. This may help to reduce the occurrence of
"hot spots" in
use in locations where these are not desired. The part of the aperture that is
curved may be
provided in the aerosolisable material feed section.
In some examples, one, more, or each curved, elongate aperture is curved along
substantially its entire length.
In some examples, the aerosol generating component is substantially planar.
In some examples, the curvature of one, more, or each curved, elongate
aperture is in the
plane of the substantially planar aerosol generating component.
In some examples, one, more, or each curved, elongate aperture comprises a
curved
portion connected to a straight portion.
In some examples, one, more, or each curved, elongate aperture comprises a
slot portion
connected to a slit portion.
In some examples, the width of the slot portion is greater than 0.3 mm.
In some examples, the width of the slot portion is greater than 0.3 mm, or at
least 0.35
mm. In some examples, the width of the slot portion is up to 3 mm, or up to
2.5 mm, or up to 2
mm, or up to 1.5 mm, or up to 1 mm, or up to 0.8 mm, or up to 0.7 mm, or up to
0.6 mm, or up to
0.55 mm. In some examples, the width of the slot portion is greater than 0.3
mm and up to 1 mm,
or greater than 0.3 mm and up to 0.8 mm, or greater than 0.3 mm and up to 0.6
mm, or greater
than 0.3 mm and up to 0.55 mm. In some examples, the width of the slot portion
is between 0.25
mm and 1 mm, or between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or
between
0.35 mm and 0.55 mm, or between 0.4 mm and 0.5 mm.
In some examples, the width of the slit portion is up to 0.3 mm.
The width of the slit portion is greater than 0 mm. In some examples, the slit
portion has
a width of up to 0.25 mm. In some examples, the width of the slit portion is
at least 0.05 mm, or
at least 0.1 mm, or at least 0.15 mm. In some examples, the width of the slit
portion is between
0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm and 0.25
mm. In
some examples, the width of the slit portion is about 0.2 mm.
In some examples, one, more, or each curved, elongate aperture is open at the
periphery
of the aerosol generating component.
In some examples, one, more, or each curved, elongate aperture is enclosed by
the
periphery of the aerosol generating component.
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In some examples, the aerosol generating component comprises: an aerosolisable
material feed section configured to receive aerosolise aerosolisable material;
and an
aerosolisation section configured to aerosolise aerosolisable material.
In some examples, one, more, or each curved, elongate aperture comprises a
slot portion
connected to a slit portion, and one, more, or each slot portion is provided
in the aerosolisation
section.
In some examples, one, more, or each curved, elongate aperture comprises a
slot portion
connected to a slit portion and one, more, or each slit portion is provided in
the aerosolisable
material feed section.
In some examples, the aerosol generating component comprises one or more
electrical
connectors.
In some examples, the aerosol generating component is formed of a porous
material.
In some examples, the aerosol generating component is formed of an
electrically
conductive material.
In some examples, the aerosol generating component is formed of a single
layer.
In some examples, the aerosol generating component is formed from a woven or
weave
structure, mesh structure, fabric structure, open-pored fiber structure, open-
pored sintered
structure, open-pored foam or open-pored deposition structure.
In one aspect of the present disclosure, there is provided an article
comprising. an aerosol
generating component according to a previous aspect; and one or more of an
aerosol forming
chamber and a reservoir for aerosolisable material.
In one aspect of the present disclosure, there is provided a non-combustible
aerosol
provision system comprising: an article according to a previous aspect; and a
device comprising
one or more of a power source and a controller.
In one aspect of the present disclosure, there is provided an article for use
in a non-
combustible aerosol provision system, the article comprising: a housing; and a
substantially
planar aerosol generating component having at least one elongate slot, the
aerosol generating
component being at least partially housed within the housing, the housing
defining a capillary gap
through which aerosolisable material can be fed to the aerosol generating
component, wherein
the capillary gap and the one, more, or each elongate slot do not overlap.
The substantially planar aerosol generating component may comprise multiple
elongate
slots as defined herein.
In some examples, one, more or each elongate slot is provided inboard of the
capillary
gap.
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In some examples, one, more or each elongate slot is connected to an elongate
slit so as
to provide at least one elongate aperture.
In some examples, one, more, or each elongate slit and the capillary gap
overlap.
In some examples, the width of one, more, or each elongate slit is greater
than 0 mm. In
some examples, the width of one, more, or each elongate slit is up to 0.3 mm,
or up to 0.25 mm.
In some examples, the width of one, more, or each elongate slit is at least
0.05 mm, or at least
0.1 mm, or at least 0.15 mm. In some examples, the width of one, more, or each
elongate slit is
between 0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm, or between 0.15 mm
and 0.25
mm. In some examples, the width of one, more, or each elongate slit is about
0.2 mm.
In some examples, the width of one, more, or each elongate slot is greater
than 0.3 mm,
or at least 0.35 mm. In some examples, the width of one, more, or each
elongate slot is up to 3
mm, or up to 2.5 mm, or up to 2 mm, or up to 1.5 mm, or up to 1 mm, or up to
0.8 mm, or up to
0.7 mm, or up to 0.6 mm, or up to 0.55 mm. In some examples, the width of one,
more, or each
elongate slot is greater than 0.3 mm and up to 1 mm, or greater than 0.3 mm
and up to 0.8 mm,
or greater than 0.3 mm and up to 0.6 mm, or greater than 0.3 mm and up to 0.55
mm. In some
examples, the width of one, more, or each elongate slot is between 0.25 mm and
1 mm, or
between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or between 0.35 mm
and 0.55
mm, or between 0.4 mm and 0.5 mm.
In some examples, the aerosol generating component is substantially planar.
In some examples, the aerosol generating component comprises an aerosolisable
material feed section configured to receive aerosolise aerosolisable material;
and an
aerosolisation section configured to aerosolise aerosolisable material.
In some examples, one, more or each slot is provided in the aerosolisation
section.
In some examples, the aerosolisation section and the capillary gap do not
overlap.
In some examples, the aerosolisation section is provided inboard of the
capillary gap.
In some examples, the aerosolisable material feed section and the capillary
gap overlap.
In some examples, one, more or each elongate slot is connected to an elongate
slit so as
to provide at least one elongate aperture, and wherein one, more, or each slit
is provided in the
aerosolisable material feed section.
In some examples, the housing comprises a first carrier component and a second
carrier
component that are spaced apart so as to define the capillary gap between the
first carrier
component and the second carrier component.
In some examples, the aerosol generating component comprises one or more
electrical
connectors.
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In some examples, the aerosol generating component is formed of a porous
material.
In some examples, the aerosol generating component is formed of an
electrically
conductive material.
In some examples, the aerosol generating component is formed of a single
layer.
In some examples, the aerosol generating component is formed from a woven or
weave
structure, mesh structure, fabric structure, open-pored fiber structure, open-
pored sintered
structure, open-pored foam or open-pored deposition structure.
In some examples, the article comprises and one or more of an aerosol forming
chamber
and a reservoir for aerosolisable material.
In one aspect of the present disclosure, there is provided a non-combustible
aerosol
provision system comprising: an article according to a previous aspect of the
present disclosure;
and a device comprising one or more of a power source and a controller.
It is possible to configure the system such that the airflow channel(s) and/or
the aerosol
generating chamber(s) and/or the aerosol generating component(s) are
separable. For
example, the article may be provided in a modular form in which the airflow
channel(s) and/or
the aerosol generating chamber(s) and/or the aerosol generating component(s)
are separable.
According to another aspect of the present disclosure, there is provided:
Al. An aerosol generating component comprising at least one
curved, elongate
aperture.
A2. An aerosol generating component of clause Al, wherein one, more, or
each
curved, elongate aperture increases in curvature from one end of the aperture
to the other end
of the aperture.
A3. An aerosol generating component of clause Al or A2, wherein
one, more, or
each curved, elongate aperture is curved along at least part of its length.
A4. An aerosol generating component of any one of clauses Al-A3, wherein
one,
more, or each curved, elongate aperture is curved along substantially its
entire length.
A5. An aerosol generating component of any one of clauses Al-A4, wherein
the
aerosol generating component is substantially planar.
A6. An aerosol generating component of any one of clauses Al-A5, wherein
one,
more, or each curved, elongate aperture comprises a curved portion connected
to a straight
portion.
A7. An aerosol generating component of any one of clauses Al-A6, wherein
one,
more, or each curved, elongate aperture comprises a slot portion connected to
a slit portion.
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A8. An aerosol generating component of clause A7, wherein the width of the
slot
portion is greater than 0.3 mm, and the width of the slit portion is up to 0.3
mm.
A9. An aerosol generating component of any one of clauses Al-A8, wherein
one,
more, or each curved, elongate aperture is open at the periphery of the
aerosol generating
component.
A10. An aerosol generating component of any one of clauses Al-A9, wherein one,
more, or each curved, elongate aperture is enclosed by the periphery of the
aerosol generating
component.
A11. An aerosol generating component of any one of clauses Al-Al 0,
comprising: an
aerosolisable material feed section configured to receive aerosolise
aerosolisable material; and
an aerosolisation section configured to aerosolise aerosolisable material.
Al2. An aerosol generating component of clause All, wherein one, more, or each
curved, elongate aperture comprises a slot portion connected to a slit
portion, and one, more, or
each slot portion is provided in the aerosolisation section.
A13. An aerosol generating component of clause All or Al2, wherein one, more,
or
each curved, elongate aperture comprises a slot portion connected to a slit
portion and one,
more, or each slit portion is provided in the aerosolisable material feed
section.
A14. An aerosol generating component of any one of clauses Al-A13, comprising
one
or more electrical connectors_
A15. An aerosol generating component of any one of clauses Al-Al 4, wherein
the
aerosol generating component is formed of a porous material.
A16. An aerosol generating component of any one of clauses Al-A15, wherein the
aerosol generating component is formed of an electrically conductive material.
A17. An aerosol generating component of any one of clauses Al-Al 6, wherein
the
aerosol generating component is formed of a single layer.
A18. An aerosol generating component of any one of clauses Al-Al 7, wherein
the
aerosol generating component is formed from a woven or weave structure, mesh
structure,
fabric structure, open-pored fiber structure, open-pored sintered structure,
open-pored foam or
open-pored deposition structure.
A19. An article comprising: an aerosol generating component of any one of
clauses
Al-Al 8; and one or more of an aerosol forming chamber and a reservoir for
aerosolisable
material.
A20. A non-combustible aerosol provision system comprising: an article of
clause A19;
and a device comprising one or more of a power source and a controller.
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According to another aspect of the present disclosure, there is provided:
Bl. An article for use in a non-combustible aerosol provision
system, the article
comprising: a housing; and a substantially planar aerosol generating component
having at least
one elongate slot, the aerosol generating component being at least partially
housed within the
housing, the housing defining a capillary gap through which aerosolisable
material can be fed to
the aerosol generating component, wherein the capillary gap and one, more, or
each elongate
slot do not overlap.
B2. An article of clause B1, wherein one, more or each elongate
slot is provided
inboard of the capillary gap.
B3. An article of clause B1 or B2, wherein one, more, or each elongate slot
is
connected to an elongate slit so as to provide at least one elongate aperture.
B4. An article of any one of clauses B1-133, wherein one, more, or each
elongate slit
and the capillary gap overlap.
B5. An article of any one of clauses B1-134, wherein the aerosol generating
component is substantially planar.
B6. An article of any one of clauses B1-135, wherein the aerosol generating
component comprises an aerosolisable material feed section configured to
receive aerosolise
aerosolisable material; and an aerosolisation section configured to aerosolise
aerosolisable
material.
B7. An article of clause B6, wherein one, more, or each elongate slot is
provided in
the aerosolisation section.
B8. An article of clause B6 or B7, wherein the aerosolisation section and
the capillary
gap do not overlap.
B9. An article of any one of clauses B6-138, wherein the aerosolisation
section is
provided inboard of the capillary gap.
B10. An article of any one of clauses B6-139, wherein the aerosolisable
material feed
section and the capillary gap overlap.
B11. An article of any one of clauses B6-610, wherein one, more, or each
elongate
slot is connected to an elongate slit so as to provide at least one elongate
aperture, and wherein
one, more, or each slit is provided in the aerosolisable material feed
section.
B12. An article of any one of clauses B1-1311, wherein the housing comprises a
first
carrier component and a second carrier component that are spaced apart so as
to define the
capillary gap.
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613. An article of any one of clauses B1-1312, wherein the aerosol generating
component comprises one or more electrical connectors.
614. An article of any one of clauses B1-1313, comprising and one or more of
an
aerosol forming chamber and a reservoir for aerosolisable material.
615. An article of any one of clauses B1-1314, wherein the aerosol generating
component is formed of a porous material.
616. An article of any one of clauses B1-1315, wherein the aerosol generating
component is formed of an electrically conductive material.
617. An article of any one of clauses B1-616, wherein the aerosol generating
component is formed of a single layer.
618. An article of any one of clauses B1-1317, wherein the aerosol generating
component is formed of a woven or weave structure, mesh structure, fabric
structure, open-
pored fiber structure, open-pored sintered structure, open-pored foam or open-
pored deposition
structure.
B19. A non-combustible aerosol provision system comprising: an article of any
one of
clauses 131-1316; and a device comprising one or more of a power source and a
controller.
It will be appreciated that 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
combined with, embodiments of the invention according to other aspects of the
invention as
appropriate, and not just in the specific combinations described above.
Brief Description of the Drawings
Various embodiments will now be described in detail by way of example only
with
reference to the accompanying drawings in which:
Figure 1 is a schematic representation of an aerosol provision system
according to the
present disclosure.
Figure 2A is a diagram of an article for use as part of an aerosol provision
system
according to the present disclosure.
Figure 26 is a diagram of a part of the article of Fig. 2A.
Figure 2C is a cross sectional view of the article of Fig. 2A.
Figure 2D is a front view of the article of Fig. 2A.
Figure 2E is a rear view of the article of Fig. 2A.
Figure 3A-C are diagrams of exemplary aerosol generating components for use in
the
article of Figure 2.
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Figure 4 is a diagram of an exemplary aerosol generating component for use in
the
article of Figure 2.
Detailed Description
Aspects and features of certain examples and embodiments are
discussed/described
herein. Some aspects and features of certain examples and embodiments may be
implemented
conventionally and these are not discussed/described in detail in the
interests of brevity. It will
thus be appreciated that aspects and features of apparatus and methods
discussed herein which
are not described in detail may be implemented in accordance with any
conventional techniques
for implementing such aspects and features.
As described above, the present disclosure relates, but is not limited, to non-
combustible
aerosol provision systems and devices that generate an aerosol from an aerosol-
generating
material (also referred to herein as aerosolisable material) without
combusting the aerosol-
generating material. Examples of such systems include electronic cigarettes,
tobacco heating
systems, and hybrid systems (which generate aerosol using a combination of
aerosol-
generating materials). In some examples, 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 of the present disclosure In some examples, 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
examples,
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 in such a hybrid 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 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.
Throughout the following description the terms "e-cigarette" and "electronic
cigarette"
may sometimes be used. However, it will be appreciated these terms may be used
interchangeably with non-combustible aerosol (vapour) provision system or
device as explained
above.
In some examples, the present disclosure relates to consumables for holding
aerosol-
generating material, and which are configured to be used with non-combustible
aerosol
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provision devices. These consumables may be referred to as articles throughout
the present
disclosure.
The non-combustible aerosol provision system typically comprises a device part
(also
referred to herein as a device) and a consumable/article part (also referred
to herein as an
article). The device part typically comprises a power source and a controller.
The power source
may typically be an electrical power source, e.g. a rechargeable battery.
In some examples, the non-combustible aerosol provision system may comprise an
area
for receiving or engaging with the consumable/article, an aerosol generator
(which may or may
not be within the consumable/article), an aerosol generation area (which may
be within the
consumable/article), a housing, a mouthpiece, a filter and/or an aerosol-
modifying agent.
In some examples, the consumable/article for use with the non-combustible
aerosol
provision device may comprise aerosol-generating material, an aerosol-
generating material
storage area (also referred to herein as a reservoir for aerosolisable
material), an aerosol-
generating material transfer component (e.g. a wick, such as a pad), an
aerosol generator (also
referred to herein as an aerosol generating component), an aerosol generation
area (also
referred to herein as an aerosol generation chamber), a housing, a wrapper, a
filter, a
mouthpiece, and/or an aerosol-modifying agent.
The systems described herein typically generate an inhalable aerosol by
vaporisation of
an aerosol generating material. The aerosol generating material may comprise
one or more
active constituents, one or more flavours, one or more aerosol-former
materials, and/or one or
more other functional materials.
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 flavourants. 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. The amorphous solid is a solid material that may retain
some fluid, such as
liquid, within it. In some examples, the aerosol-generating material may for
example comprise
from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or
100wt% of
amorphous solid.
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, nootropics,
psychoactives.
The active substance may be naturally occurring or synthetically obtained. The
active substance
may comprise for example nicotine, caffeine, taurine, theine, vitamins such as
B6 or B12 or C,
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melatonin, cannabinoids, or constituents, derivatives, or combinations
thereof. The active
substance may comprise one or more constituents, derivatives or extracts of
tobacco, cannabis
or another botanical.
The aerosol-former material may comprise one or more constituents capable of
forming
an aerosol. In some examples, the aerosol-former material may comprise one or
more of
glycerol, propylene glycol, diethylene glycol, triethylene glycol,
tetraethylene glycol, 1,3-butylene
glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, 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.
As used herein, the term "component" is used to refer to a part, section,
unit, module,
assembly or similar of an electronic cigarette or similar device that
incorporates several smaller
parts or elements, possibly within an exterior housing or wall. An electronic
cigarette may be
formed or built from one or more such components, and the components may be
removably or
separably connectable to one another, or may be permanently joined together
during
manufacture to define the whole electronic cigarette. The present disclosure
is applicable to (but
not limited to) systems comprising two components separably connectable to one
another and
configured, for example, as a consumable/article component capable of holding
an aerosol
generating material (also referred to herein as a cartridge or cartomiser),
and a device/control
unit having a battery for providing electrical power to operate an element for
generating vapour
from the aerosol generating material.
Fig. 1 is a highly schematic diagram (not to scale) of an example
aerosol/vapour provision
system such as an e-cigarette 10. The e-cigarette 10 has a generally
cylindrical shape, extending
along a longitudinal axis indicated by a dashed line, and comprises two main
components, namely
a control or power component or section 20 (which may be referred to herein as
a device) and a
cartridge assembly or section 30 (which may be referred to herein as an
article, consumable,
cartomizer, or cartridge) that operates as a vapour generating component.
The cartridge assembly 30 includes a storage compartment (also referred to
herein as a
reservoir) 3 containing an aerosolisable material comprising (for example) a
liquid formulation
from which an aerosol is to be generated, for example containing nicotine. As
an example, the
aerosolisable material may comprise around 1 to 3% nicotine and 50% glycerol,
with the
remainder comprising roughly propylene glycol, and possibly also comprising
other components,
such as water or flavourings. The storage compartment 3 has the form of a
storage tank, being a
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container or receptacle in which aerosolisable material can be stored such
that the aerosolisable
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 absorbent material such as cotton
wadding or glass
fibre which holds the aerosolisable material within a porous structure. The
storage compartment
3 may be sealed after filling during manufacture so as to be disposable after
the aerosolisable
material is consumed, or may have an inlet port or other opening through which
new aerosolisable
material can be added. The cartridge assembly 30 also comprises an electrical
aerosol generating
component 4 located externally of the reservoir tank 3 for generating the
aerosol by vaporisation
of the aerosolisable material. In many examples, the aerosol generating
component may be a
heating element (heater) which is heated by the passage of electrical current
(via resistive or
inductive heating) to raise the temperature of the aerosolisable material
until it evaporates. A
liquid conduit arrangement such as a wick or other porous element (not shown)
may be provided
to deliver aerosolisable material from the storage compartment 3 to the
aerosol generating
component 4. The wick may have one or more parts located inside the storage
compartment 3
so as to be able to absorb aerosolisable material and transfer it by wicking
or capillary action to
other parts of the wick that are in contact with the aerosol generating
component 4. This
aerosolisable material is thereby vaporised, and is to be replaced by new
aerosolisable material
transferred to the aerosol generating component 4 by the wick.
A heater and wick combination, or other arrangement of parts that perform the
same
functions, is sometimes referred to as an atomiser or atomiser assembly.
Various designs are
possible, in which the parts may be differently arranged compared to the
highly schematic
representation of Fig. 1. For example, the wick may be an entirely separate
element from the
aerosol generating component, or the aerosol generating component may be
configured to be
porous and able to perform the wicking function directly (by taking the form
of a suitable
electrically resistive mesh or capillary body, for example).
In some cases, the conduit for delivering liquid for vapour generation may be
formed at
least in part from one or more slots, tubes or channels between the storage
compartment and the
aerosol generating component which are narrow enough to support capillary
action to draw
source liquid out of the storage compartment and deliver it for vaporisation.
In general, an
atomiser can be considered to be an aerosol generating component able to
generate vapour from
aerosolisable material delivered to it, and a liquid conduit (pathway) able to
deliver or transport
liquid from a storage compartment or similar liquid store to the aerosol
generating component by
a capillary force.
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Typically, the aerosol generating component is at last partly located within
an aerosol
generating chamber that forms part of an airflow channel through the
electronic cigarette/system.
Vapour produced by the aerosol generating component is driven off into this
chamber, and as air
passes through the chamber, flowing over and around the aerosol generating
element, it collects
the produced vapour whereby it condenses to form the required aerosol.
Returning to Fig. 1, the cartridge assembly 30 also includes a mouthpiece 35
having an
opening or air outlet through which a user may inhale the aerosol generated by
the aerosol
generating component 4, and delivered through the airflow channel.
The power component 20 includes a cell 5 (also referred to herein as a
battery, and which
may be re-chargeable) to provide power for electrical components of the e-
cigarette 10, in
particular the aerosol generating component 4. Additionally, there is a
printed circuit board 28
and/or other electronics or circuitry for generally controlling the e-
cigarette. The control
electronics/circuitry connect the vapour generating element 4 to the battery 5
when vapour is
required, for example in response to a signal from an air pressure sensor or
air flow sensor (not
shown) that detects an inhalation 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
channel. When the
aerosol generating component 4 receives power from the battery 5, the aerosol
generating
component 4 vaporises aerosolisable material delivered from the storage
compartment 3 to
generate the aerosol, and this is then inhaled by a user through the opening
in the mouthpiece
35. The aerosol is carried to the mouthpiece 35 along the airflow channel (not
shown) that
connects the air inlet 26 to the air outlet when a user inhales on the
mouthpiece 35. An airflow
path through the electronic cigarette is hence defined, between the air
inlet(s) (which may or may
not be in the power component) to the atomiser and on to the air outlet at the
mouthpiece. In use,
the air flow direction along this airflow path is from the air inlet to the
air outlet, so that the atomiser
can be described as lying 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 detachable from one another by separation in a direction
parallel to the longitudinal
axis, as indicated by the solid arrows in Fig. 1. The components 20, 30 are
joined together when
the device 10 is in use by cooperating engagement elements 21, 31 (for
example, a screw,
magnetic or bayonet fitting) which provide mechanical and electrical
connectivity between the
power section 20 and the cartridge assembly 30. This is merely an example
arrangement,
however, and the various components may be differently distributed between the
power section
20 and the cartridge assembly section 30, and other components and elements
may be included.
The two sections may connect together end-to-end in a longitudinal
configuration as in Fig. 1, or
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in a different configuration such as a parallel, side-by-side arrangement. The
system may or may
not be generally cylindrical and/or have a generally longitudinal shape_
Either or both sections
may be intended to be disposed of and replaced when exhausted (the reservoir
is empty or the
battery is flat, for example), or be intended for multiple uses enabled by
actions such as refilling
the reservoir, recharging the battery, or replacing the atomiser.
Alternatively, the e-cigarette 10
may be a unitary device (disposable or refillable/rechargeable) that cannot be
separated into two
or more parts, in which case all components are comprised within a single body
or housing.
Examples of the present invention are applicable to any of these
configurations and other
configurations of which the skilled person will be aware.
As mentioned, a type of aerosol generating component, such as a heating
element, that
may be utilised in an atomising portion of an electronic cigarette (a part
configured to generate
vapour from a source liquid) combines the functions of heating and liquid
delivery, by being both
electrically conductive (resistive) and porous. Note here that reference to
being electrically
conductive (resistive) refers to components which have the capacity to
generate heat in response
to the flow of electrical current therein. Such flow could be imparted by via
so-called resistive
heating or induction heating. An example of a suitable material for this is an
electrically conductive
material such as a metal or metal alloy formed into a sheet-like form, i.e. a
planar shape with a
thickness many times smaller than its length or breadth. Examples in this
regard may be a mesh,
web, grill and the like_ The mesh may be formed from metal wires or fibres
which are woven
together, or alternatively aggregated into a non-woven structure. For example,
fibres may be
aggregated by sintering, in which heat and/or pressure are applied to a
collection of metal fibres
to compact them into a single porous mass. It is possible for the planar
aerosol generating
component to define a curved plane and in these instances reference to the
planar aerosol
generating component forming a plane means an imaginary flat plane forming a
plane of best fit
through the component.
These structures can give appropriately sized voids and interstices between
the metal
fibres to provide a capillary force for wicking liquid. Thus, these structures
can also be considered
to be porous since they provide for the uptake and distribution of liquid.
Moreover, due to the
presence of voids and interstices between the metal fibres, it is possible for
air to permeate
through said structures. Also, the metal is electrically conductive and
therefore suitable for
resistive heating, whereby electrical current flowing through a material with
electrical resistance
generates heat. Structures of this type are not limited to metals, however.
oOther conductive
materials may be formed into fibres and made into mesh, grill or web
structures. Examples include
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ceramic materials, which may or may not be doped with substances intended to
tailor the physical
properties of the mesh.
A planar sheet-like porous aerosol generating component of this kind can be
arranged
within an electronic cigarette such that it lies within the aerosol generating
chamber forming part
of an airflow channel. The aerosol generating component may be oriented within
the chamber
such that air flow though the chamber may flow in a surface direction, i.e.
substantially parallel to
the plane of the generally planar sheet-like aerosol generating component. An
example of such
a configuration can be found in W02010/045670 and W02010/045671, the contents
of which are
incorporated herein in their entirety by reference. Air can thence flow over
the heating element,
and gather vapour. Aerosol generation is thereby made very effective. In
alternative examples,
the aerosol generating component may be oriented within the chamber such that
air flow though
the chamber may flow in a direction which is substantially transverse to the
surface direction, i.e.
substantially orthogonally to the plane of the generally planar sheet-like
aerosol generating
component. An example of such a configuration can be found in W02018/211252,
the contents
of which are incorporated herein in its entirety by reference.
The aerosol generating component may have, and/or be formed of, any one of the
following structures: a woven or weave structure, mesh structure, fabric
structure, open-pored
fiber structure, open-pored sintered structure, open-pored foam or open-pored
deposition
structure. Said structures are suitable in particular for providing an aerosol
generating
component with a high degree of porosity. A high degree of porosity may ensure
that the heat
produced by the aerosol generating component is predominately used for
evaporating the liquid
and high efficiency can be obtained. A porosity of greater than 50% may be
envisaged with said
structures. In one embodiment, the porosity of the aerosol generating
component is 50% or
greater, 60% or greater, 70% or greater. The open-pored fiber structure can
consist, for
example, of a non-woven fabric which can be arbitrarily compacted, and can
additionally be
sintered in order to improve the cohesion. The open-pored sintered structure
can consist, for
example, of a granular, fibrous or flocculent sintered composite produced by a
film casting
process. The open-pored deposition structure can be produced, for example, by
a CVD
process, PVD process or by flame spraying. Open-pored foams are in principle
commercially
available and are also obtainable in a thin, fine-pored design.
In one embodiment, the aerosol generating component is formed from a single
layer. In
one embodiment, the aerosol generating component has at least two layers,
wherein the layers
contain at least one of the following structures: a plate, foil, paper, mesh,
woven structure,
fabric, open-pored fiber structure, open-pored sintered structure, open-pored
foam or open-
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pored deposition structure. For example, the aerosol generating component can
be formed by
an electric heating resistor consisting of a metal foil combined 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 metal wire fabric, or from a
non-woven metal
fiber fabric. Individual layers are advantageously but not necessarily
connected to one another
by a heat treatment, such as sintering or welding. For example, the aerosol
generating
component can be designed as a sintered composite consisting of a stainless
steel foil and one
or more layers of a stainless steel wire fabric (material, for example AISI
304 or AISI 316).
Alternatively, the aerosol generating component can be designed as a sintered
composite
consisting of at least two layers of a stainless steel wire fabric. The layers
may be connected to
one another by spot welding or resistance welding. Individual layers may also
be connected to
one another mechanically. For instance, a double-layer wire fabric could be
produced just by
folding a single layer. Instead of stainless steel, use may also be made, by
way of example, of
heating conductor alloys-in particular NiCr alloys and CrFeAl alloys
("Kanthal") which have an
even higher specific electric resistance than stainless steel. The material
connection between
the layers is obtained by the heat treatment, as a result of which the layers
maintain contact
with one another-even under adverse conditions, for example during heating by
the aerosol
generating component and resultantly induced thermal expansions.
Alternatively, the aerosol
generating component may be formed from sintering a plurality of individual
fibers together.
Thus, the aerosol generating component can be comprised of sintered fibers,
such as sintered
metal fibers.
The aerosol generating component may comprise, for example, an electrically
conductive thin layer of electrically resistive material, such as platinum,
nickel, molybdenum,
tungsten or tantalum, said thin layer being applied to a surface of the
vaporizer by a PVD or
CVD process, or any other suitable process. In this case, the aerosol
generating component
may comprise an electrically insulating material, for example of ceramic.
Examples of suitable
electrically resistive material include stainless steels, such as AISI 304 or
AISI 316, and heating
conductor alloys-in particular NiCr alloys and CrFeAl alloys ("Kanthal"), such
as DIN material
number 2,4658, 2,4867, 2,4869, 2,4872, 1,4843, 1,4860, 1,4725, 1,4765 and
1,4767.
As described above, the aerosol generating component may be formed from a
sintered
metal fiber material and may be in the form of a sheet. Material of this sort
can be thought of a
mesh or irregular grid, and is created by sintering together a randomly
aligned arrangement or
array of spaced apart metal fibers or strands. A single layer of fibers might
be used, or several
layers, for example up to five layers. As an example, the metal fibers may
have a diameter of 8
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to 12 pm, arranged to give a sheet of thickness 0.16 mm, and spaced to produce
a material
density of from 100 g/m2 to 1500 g/m2, such as from 150 g/m2 to 1000 g/m2, 200
g/m2 to 500
g/m2, or 200 to 250 g/m2, and a porosity of 84%. The sheet thickness may also
range from
0.1mm to 0.2mm, such as 0.1mm to 0.15mm. Specific thicknesses include 0.10 mm,
0.11 mm,
0.12mm, 0.13 mm, 0.14 mm, 0.15 mm 0r0.1 mm. Generally, the aerosol generating
component has a uniform thickness. However, it will be appreciated from the
discussion below
that the thickness of the aerosol generating component may also vary. This may
be due, for
example, to some parts of the aerosol generating component having undergone
compression.
Different fiber diameters and thicknesses may be selected to vary the porosity
of the aerosol
generating component. For example, the aerosol generating component may have a
porosity
of 66% or 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 generally flat structure,
comprising first
and second surfaces. The generally flat 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.
A width and/or length of the aerosol generating component may be from about 1
mm to
about 50mm. For example, the width and/or length of the vaporizer may be from
1 mm, 2 mm,
3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm. The width may generally be
smaller
than the length of the aerosol generating component. It will be understood
that the dimensions
of the aerosol generating component may be varied.
Where the aerosol generating component is formed from an electrically
resistive
material, electrical current is permitted to flow through the aerosol
generating component so as
to generate heat (so called Joule heating). In this regard, the electrical
resistance of the aerosol
generating component can be selected appropriately. For example, the aerosol
generating
component may have an electrical resistance of 2 ohms or less, such as 1.8ohms
or less, such
as 1.7ohms or less, such as 1.6ohms or less, such as 1.5ohms or less, such as
1.4ohms or
less, such as 1.3ohms or less, such as 1.2ohms or less, such as 1.1ohms or
less, such as
1.00hm or less, such as 0.9ohms or less, such as 0.8ohms or less, such as
0.7ohms or less,
such as 0.6ohms or less, such as 0.5ohms or less. The parameters of the
aerosol generating
component, such as material, thickness, width, length, porosity etc. can be
selected so as to
provide the desired resistance. In this regard, a relatively lower resistance
will facilitate higher
power draw from the power source, which can be advantageous in producing a
high rate of
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aerosolisation. On the other hand, the resistance should not be so low so as
to prejudice the
integrity of the aerosol generator. For example, the resistance may not be
lower than 0.5 ohms.
Planar aerosol generating components, such as heating elements, suitable for
use in
systems, devices and articles disclosed herein may be formed by stamping or
cutting (such as
laser cutting) the required shape from a larger sheet of porous material. This
may include
stamping out, cutting away or otherwise removing material to create openings
in the aerosol
generating component. These openings can influence both the ability for air to
pass through the
aerosol generating component and the propensity for electrical current to flow
in certain areas.
Fig. 2A-C show diagrams (not to scale) of an exemplary article 100 for use in
a non-
combustible aerosol/vapour provision system 10, according to the present
disclosure. In general
terms, the article 100 comprises a housing 101, 102, which may comprise a
carrier assembly.
The carrier assembly may comprise a first carrier component 101 and a second
carrier component
102. The article 100 may comprise an aerosol generating component 103 (see
Fig. 2B). The
aerosol generating component 103 may be at least partially housed within the
housing 101, 102
(e.g. within the carrier assembly). The housing (and in the case of this
example, the first and
second carrier components 101, 102) plays a role in supporting the aerosol
generating component
103. Thus, for convenience, and having regard to the orientation represented
in the figures, the
first and second carrier components 101, 102 also may be considered as a lower
cradle
component 101 and an upper cradle component 102. The housing may define a gap
G (see Fig.
2A) through which aerosolisable material can be fed to the aerosol generating
component 103.
In this example, the first and second carrier components 101, 102 are
separated by a distanced.
This separation provides the gap G through which aerosolisable material can be
fed to the aerosol
generating component 103 in use (e.g. from a reservoir, which is not shown in
the Figs.). The gap
G provides a capillary channel (one each side) which extends along both sides
of the aerosol
generating component 103. In some examples, the aerosol generating component
103 is a
substantially planar heating element 103.
The article 100 may comprise first and second electrical contact elements for
connecting
to the aerosol generating component 103 (e.g. corresponding first and second
electrical
connectors of the aerosol generating component 103). The first and second
electrical contact
elements may be formed of a sheet metal material, for example comprising
metallic strips formed
into an appropriate shape having regard to the shape and configuration of the
other elements of
the apparatus in accordance with conventional manufacturing techniques, or may
comprise
conventional flexible wiring. In embodiments where electrical energy is
inductively coupled to the
aerosol generating component it will be understood that such contact elements
are not required.
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The carrier assembly, e.g. the first and second carrier components 101, 102,
may be
moulded from a plastics material having a high glass fibre content (e.g at or
great than around
50%) to provide improved rigidity and resistance to high temperatures, for
example temperatures
around 230 degrees centigrade.
The first and second carrier components 101, 102 may be provided in various
forms and
dimensions. The carrier assembly is constructed so that when the two carrier
components 101,
102 are brought together to sandwich the aerosol generating component 103
therebetween, the
carrier components 101, 102 form the carrier assembly with an airflow path 110
running down the
interior of the carrier assembly and in which the aerosol generating component
103 is at least
partially disposed. The airflow path 110 comprises an aerosol generation
chamber. The carrier
assembly may take on an elongate form, or may have width and length dimensions
that are
similar. Moreover, the form and dimensions of the airflow path may be varied.
In the example of Figs. 2A-C, the first carrier component 101 has an upstream
portion
104, a downstream portion 105 (shown in Fig. 2A), and two side edges 106 (the
right edge being
shown in Fig. 2A). As shown in Figs. 2B and C, the second carrier component
102 has an
upstream portion 107, a downstream portion 108, and two side edges 109. The
first carrier
component 101 and the second carrier component 102 have substantially the same
width
(measured from side edge to side edge). An air inlet 113 is provided at the
upstream portion 104
of the first carrier component 101 (see Fig. 2C), and an air outlet 114 is
provided at the
downstream portion 108 of the second carrier component 102 (see Figs. 2B and
C). From Fig.
2C in particular, it can be seen that, in use, air flows into the air inlet
113, along the airflow path
110, and through the outlet 114.
The first carrier component 101 and the second carrier component 102 may be
attached
together by any suitable means, such as by a clearance fit, a transition fit,
or an interference fit.
Other attachments are envisaged. In some examples, for example the specific
example of Fig. 2,
the first carrier component 101 and the second carrier component 102 may be
attached together
by a snap fit. For example, one or more of the first carrier component 101 and
the second carrier
component 102 may comprise one or more projections configured to engage (e.g.
via a snap fit)
with a corresponding portion of the other of the first carrier component 101
and the second carrier
component 102. In the example of Figs. 2A-E, the first carrier component 101
comprises a pair
of projections 120 provided towards its downstream portion 105, which
projections 120 being
configured to engage via a snap-fit with a corresponding ledge 121 of the
second carrier
component 102; and the second carrier component 102 comprises a projection 122
provided at
its upstream portion 107, which projection 122 being configured to engage via
a snap-fit with a
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corresponding ledge 123 of the first carrier component 101. It will be
understood that the nature
of the attachment between the first carrier component 101 and the second
carrier component 102
may be varied.
The aerosol generating component 103 may be formed of a porous material. For
example,
the aerosol generating component 103 may be formed of a conductive material.
For example, the
aerosol generating component 103 may be formed of a single layer. For example,
the aerosol
generating component 103 may be formed from a woven or weave structure, mesh
structure,
fabric structure, open-pored fiber structure, open-pored sintered structure,
open-pored foam or
open-pored deposition structure. For example, the aerosol generating component
103 may be
generally in the form of a sheet. For example, the aerosol generating
component 103 may be
formed from a sintered metal fibre material and is generally in the form of a
sheet. It will be
appreciated that other porous conducting materials may equally be used.
For example, the aerosol generating component 103 may comprise a main portion
with
electrical connectors for connecting to the respective electrical contacts.
For example, the main
portion of the aerosol generating component may be generally rectangular with
a longitudinal
dimension (i.e. in a direction running between the electrical contact
extensions 103B) of around
mm, and a width of around 8 mm. Other dimensions are envisaged.
For example, the longitudinal dimension may correspond to the direction of
airflow through
the vaporisation chamber (note that in other examples, the longitudinal
dimension need not be
20 the longest dimension of the aerosol generating component 103). The
thickness of the sheet
comprising the aerosol generating component 103 may be around 0.15 mm. Other
dimensions
are envisaged.
The aerosol generating component 103 may comprise one or more apertures 200
(e.g.
elongate apertures). In some examples, the aperture(s) 200 may comprise one or
more elongate
apertures extending inwardly from each of the longer sides (sides parallel to
the longitudinal
direction). For example, the elongate apertures 200 may extend inwardly by
around 4.8 mm. For
example, the elongate apertures extending inwardly may be separated from one
another by
around 5.4 mm on each side of the aerosol generating component 103 with the
slots extending
inwardly from the opposing sides being offset from one another by around half
this spacing. In
other words, the slots may be alternately positioned along the longitudinal
sides. Other
configurations and dimensions are envisaged. A consequence of this arrangement
of slots 200 in
the aerosol generating component 103 is that current flow along the aerosol
generating
component 103 is in effect forced to follow a meandering path which results in
a concentration of
current, and hence electrical power, around the ends of the slots. In this
regard, and due to the
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presence of the elongate apertures, the aerosol generating component 103 can
be constructed
such that some areas of the aerosol generating component 103 (in this example
the meandering
path) have a greater propensity for current flow than others.
By having current follow a meandering path, a greater number of high
temperature areas
(also referred to as "hot spots") are more evenly distributed across the
aerosol generating
component 103, relative to having current follow a direct path which provides
fewer, larger high
temperature areas that are less evenly distributed across the aerosol
generating component 103.
In this way, the risk of burning of aerosolisable material and/or inadvertent
drying out of the
aerosol generating component 103 can be reduced. Also, more even heat
distribution and thus
more consistent aerosolisation (e.g. a more consistent particle size) can be
achieved.
In some examples (see e.g. Figs. 3A-C), the aerosol generating component 103
is
rotationally symmetrical about an axis through the centre of, and
perpendicular to, the plane of
the aerosol generating component 103.
The skilled person will appreciate that the article 100 can be manufactured in
various
different ways, and that the examples described herein serve as representative
examples. For
example, the manner in which the aerosol generating component 103 is arranged
in the housing,
e.g. between the second carrier component 102 and the first carrier component
101, may be
varied.
In the example of Figs 2A-E, the article 100, once assembled in an aerosol
generating
system 10 (e.g. an electronic cigarette), comprises a carrier assembly 101,
102 having an airflow
path 110 comprising an aerosol generating chamber, wherein the airflow path
110 extends
between air inlet(s) and air outlet(s) at a mouthpiece, in the system 10.
It will be appreciated that, in use, the article 100 of Fig. 2 may be
surrounded on either
side by a reservoir for aerosolisable material (not shown in the Figs.). As
discussed, the distance
between the first and second carrier components 101, 102 corresponds to a gap
G. This gap G
is in fluid communication with the reservoir, and provides a capillary channel
(one each side)
which extends along respective sides of the aerosol generating component 103.
For example, in
use, aerosolisable material is fed through the gap G and enters the pores
(where present) of the
aerosol generating component 103 for vaporisation to generate a vapour in the
aerosol generating
chamber. The passing air collects the vapour to generate an aerosol to be
drawn out of the aerosol
generating chamber and along a further part of the airflow path through the
system 10 to exit the
air outlet as a user draws on the system 10.
When installed in an electronic cigarette 10, the article 100 may be arranged
such that the
longitudinal direction of the aerosol generating component 103, corresponding
to the direction of
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airflow through the article 100 from the upstream end to the downstream end,
is aligned parallel
to the longitudinal axis of the electronic cigarette 10 for an end-to-end
system such as the Fig. 1
example, or at least parallel to the longitudinal axis of the device in a side-
by-side system having
the device arranged to the side of the article 100. This is not compulsory,
however, and in the
current description, the term "longitudinal" is intended to refer to the
dimensions and orientation
of the atomiser, in particular the dimension of the aerosol generating
component along the airflow
path from an atomiser inlet at the upstream end of the atomiser, and through
the vaporisation
chamber to the atomiser outlet at the downstream end of the atomiser.
Exemplary aspects of the present disclosure are described below.
According to an aspect of the present disclosure, there is disclosed an
aerosol generating
component comprising: at least one elongate slit, wherein the width of one,
more, or each
elongate slit is up to 0.3 mm. The present inventors have identified that the
use of slots (which
are wider than slits in the present context), which can be found in aerosol
generating components
of the prior art, can result in inadvertent leakage of aerosolisable material
therethrough. In
particular, said slots can act as a leakage path for aerosolisable material.
The present inventors
have identified that the use of a slit, which has a narrower width than a
slot, can reduce the risk
of inadvertent leakage of aerosolisable material via the aerosol generating
component. At the
same time, the use of a slit can provide additional current path, and thus
provide for an even heat
distribution over the aerosol generating component In this way, a more
consistent particle size,
and thus improved aerosolisation, can be achieved.
Figs. 3A-C and 4 illustrate exemplary aerosol generating components 103
comprising at
least one elongate slit 200 (not all are numbered for clarity). In this
aspect, the width of one, more,
or each elongate slit 200 is up to 0.3 mm. As discussed above, this width is
effective in reducing
the risk of leakage of aerosolisable material, whilst providing effective
heating and heat
distribution.
The width of one, more, or each elongate slit 200 is greater than 0 mm. In
some examples,
the width of one, more, or each elongate slit 200 is up to 0.25 mm. In some
examples, the width
of one, more, or each elongate slit 200 is at least 0.05 mm, or at least 0.1
mm, or at least 0.15
mm. In some examples, the width of one, more, or each elongate slit 200 is
between 0.05 mm
and about 0.3 mm, or between 0.05 mm and 0.3 mm, or between 0.1 mm and 0.3 mm,
or between
0.15 mm and 0.25 mm. In some examples, the width of one, more, or each
elongate slit 200 is
about 0.2 mm. A width of about 0.2 mm has been found particularly effective at
reducing the risk
of inadvertent leakage of aerosolisable material.
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In some examples, one, more, or each elongate slit 200 is substantially
straight. For
example, in the examples of Figs. 3A and 3B, each elongate slit 200 is
substantially straight
In some examples, one, more, or each elongate slit is curved.
In some examples, the aerosol generating component 103 is substantially
planar. This
configuration is shown in the figures, although it will be appreciated that
different geometries are
envisaged.
It also will be appreciated that the form of the or each elongate slit 200 can
be varied. In
some examples, one, more, or each elongate slit 200 comprises multiple
elongate slit sections.
In some examples, one, more, or each elongate slit section is substantially
straight. In some
examples, one, more, or each elongate slit section is curved (e.g. in the
plane of the substantially
planar aerosol generating component 103, such as shown in e.g. Fig. 4).
In some examples, at least two of the elongate slit sections are angled with
respect to
each other. In some examples, at least two of the elongate slit sections may
be non-parallel with
respect to each other. In some examples, at least two of the elongate slit
sections are obliquely
angled with respect to each other. For example, as shown in Fig. 3C, two of
the elongate slits 200
each comprise two slit sections, and these are obliquely angled with respect
to each other.
In some examples, one, more, or each elongate slit 200 is open at the
periphery of the
aerosol generating component 103. This configuration is illustrated, for
example, in Figs. 3B, 30
and 4. That is, in each of Figs_ 3B, 3C and 4, two slits 200 are open at the
periphery of the aerosol
generating component 103. Advantageously, this configuration helps to provide
areas of higher
current density, whilst being unlikely to present inadvertent leakage of
aerosolisable material.
In some examples, one, more, or each elongate slit 200 is enclosed by the
periphery of
the aerosol generating component. This configuration is illustrated, for
example, in Fig. 3A, 3C
and 4, wherein a number of the elongate slits 200 are enclosed by the
periphery of the aerosol
generating component 103. By virtue of the elongate slit 200 being enclosed,
the elongate slit 200
is further less likely to form a leakage path for aerosolisable material.
The aerosol generating component 103 may comprise an (e.g. at least one)
aerosolisable
material feed section 103F configured to receive aerosolisable material (e.g.
by capillary force).
Aerosolisable material feed sections 103F are illustrated, for example, in
Fig. 4, in which the
sections outboard of the respective dashed lines correspond to aerosolisable
material feed
sections 103F.
The aerosol generating component 103G may comprise an (e.g. at least one)
aerosolisation section 103G configured to aerosolise aerosolisable material.
An aerosolisation
section 103G is illustrated, for example, in Fig. 4, in which the section
delineated between the
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respective dashed lines corresponds to the aerosolisation section 103G. It is
to be understood
that in use, only the aerosolisation section 103G may reach a temperature
sufficient to aerosolise
aerosolisable material.
In some examples, the aerosol generating component 103 has a porous and/or
permeable
structure into which aerosolisable material can enter. As such, in some
examples, the aerosol
generating component 103 can take up aerosolisable material, such that it is
fed from the
aerosolisable material feed section 103F to the aerosolisation section 103F to
be aerosolised.
In some examples, one, more, or each elongate slit 200 is provided in the
aerosolisation
section 103G.
In some examples, one, more, or each elongate slit 200 is provided in the
aerosolisation
section 103G. In some examples, one, more, or each elongate slit 200 does not
extend into the
aerosolisable material feed section 103F. By providing the slit(s) in this
way, the risk of
inadvertent leakage of aerosolisable material is reduced. At the same time,
the slit(s) provide
additional current path so as to result in additional hot spots. As the total
number of hot spots
increases and the intensity of each hot spot decreases, heat distribution
across the aerosol
generating component is improved. This can result in a more consistent
particle size, and thus
improved aerosolisation.
In some examples, one, more, or each elongate slit 200 is connected to an
elongate slot
201. In such examples, the elongate slit 200 connected to the elongate slot
201 may form an
elongate aperture. In such examples, the slit 200 and the slot 201 may be
referred to respectively
as "slit portion" 200 and "slot portion" 201.
It is to be appreciated that slits and slots are forms of aperture. It is also
to be appreciated
that slots are wider than slits.
In some examples, the width of one, more, or each elongate slot 201 is greater
than 0.3
mm, or at least 0.35 mm. In some examples, the width of one, more, or each
elongate slot 201 is
up to 3 mm, or up to 2.5 mm, or up to 2 mm, or up to 1.5 mm, or up to 1 mm, or
up to 0.8 mm, or
up to 0.7 mm, or up to 0.6 mm, or up to 0.55 mm. In some examples, the width
of one, more, or
each elongate slot 201 is greater than 0.3 mm and up to 1 mm, or greater than
0.3 mm and up to
0.8 mm, or greater than 0.3 mm and up to 0.6 mm, or greater than 0.3 mm and up
to 0.55 mm. In
some examples, the width of one, more, or each elongate slot 201 is between
0.25 mm and 1
mm, or between 0.25 mm and 0.8 mm, or between 0.25 mm and 0.6 mm, or between
0.35 mm
and 0.55 mm, or between 0.4 mm and 0.5 mm.
In some examples, one, more, or each elongate slit 200 is provided in the
aerosolisable
material feed section 103F. In some examples, one, more, or each elongate slot
201 is provided
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in the aerosolisation section 103G. Thus, the use of slit(s) 200 in the
aerosolisable material feed
section 103F reduces the risk of leakage of aerosolisable material (relative
to the use of slot(s)).
Also, the use of slit(s) 200 in the aerosolisable material feed section 103F
can increase the
amount of storage for aerosolisable material in the aerosol generating
component 103 (relative
to the use of slot(s)), since less material is removed from the aerosol
generating component 103
(relative to slot(s)). Moreover, the use of slit(s) 200 in the aerosolisable
material feed section is
such that means for preventing leakage of aerosolisable material via the slit
is not necessary. By
contrast, in some aerosol generating components wherein a slot extends through
the
aerosolisable material feed section (and e.g. to the periphery of the aerosol
generating
component), means for preventing leakage of aerosolisable material via the
slot may be
necessary.
In some examples, one, more, or each elongate slit 200 extends into the
aerosolisation
section.
In the example of Fig. 4, the elongate slits 200 are connected to respective
elongate slots
201 to form respective elongate apertures. The elongate slits 200 are provided
(at least partially)
in the aerosolisable material feed section 103F, and the elongate slots 201
are provided in the
aerosolisation section 103G.
It will be understood that in some embodiments, the elongate slot 201 may
taper into the
slit 200. It will also be understood that different forms of the slit(s) 200
and the slot(s) 201 are
envisaged.
The aerosol generating component 103 may comprise one or more electrical
connectors
103C. The aerosolisation section may be provided between the electrical
connectors 103C.
The aerosol generating component may comprise any other features as defined
herein.
There is also disclosed an article 100 for use as part of a non-combustible
aerosol
provision system 10, the article 100 comprising: an aerosol generating
component 103 as defined
herein; and one or more of an aerosol forming chamber 190 and a reservoir 121
for aerosolisable
material.
There is also disclosed a non-combustible aerosol provision system 10
comprising: an
article 100 as defined herein; and a device 20 comprising one or more of a
power source and a
controller.
The system 10 may comprise any other features as defined herein.
According to one aspect, there is disclosed an aerosol generating component
comprising
at least one curved, elongate aperture. By virtue of its curved shape, the
aperture can cover a
greater surface area (between a given length) relative to a straight, elongate
aperture. In this way,
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the use of at least one curved, elongate aperture can improve the quantity
and/or distribution of
aerosol production. For example, aerosol may be produced over an increased
surface area.
By "curved", it is to be understood that the at least one curved, elongate
aperture is curved
at least in part. That is, the at least one curved, elongate aperture need not
necessarily be curved
along its entire length, but may include partial curvature (as well as e.g. a
straight part). The part
of the aperture that is curved may be provided towards the periphery of the
aerosol generating
component. This may help to reduce the occurrence of "hot spots" in use in
locations where these
are not desired. The part of the aperture that is curved may be provided in
the aerosolisable
material feed section.
Referring to Fig. 4, the aerosol generating component 103 comprises at least
one curved,
elongate aperture 200, 201. In some examples, one, more, or each curved,
elongate aperture
200, 201 increases in curvature from one end of the aperture 200, 201 to the
other end of the
aperture 200, 201. The increase in curvature may be continuous. The increase
in curvature may
begin part-way along the aperture 200, 201.
In some examples, one, more, or each curved, elongate aperture 200, 201 is
curved along
at least part of its length.
In some examples, one, more, or each curved, elongate aperture 200, 201 is
curved along
substantially its entire length.
In some examples, the aerosol generating component 103 is substantially
planar.
In some examples, one, more, or each curved, elongate aperture 200, 201 has a
substantially constant width.
In some examples, one, more, or each curved, elongate aperture 200, 201
comprises a
curved portion (or an at least partially curved portion) connected to a
substantially straight portion.
For example, as shown in Fig. 4, there are four apertures 200, 201. Two of the
apertures
200, 201 each comprise an at least partially curved portion 201 connected to a
substantially
straight portion 200. Another two of the apertures 200, 201 each comprise an
at least partially
curved portion 200 connected to a substantially straight portion 201.
In some examples, one, more, or each curved, elongate aperture 200, 201
comprises a
slot portion 201. In some examples, one, more, or each curved, elongate
aperture 200, 201
comprises a slit portion 200. In some examples, one, more, or each curved,
elongate aperture
200, 201 comprises a slot portion 201 connected to a slit portion 200. It is
to be understood that
the slot portion 201 has a greater width than the slit portion 200.
It is to be appreciated that slot portions (also referred to as "slots") are
wider than slit
portions (also referred to as "slits").
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In some examples, the width of the slot portion is greater than 0.3 mm. In
some examples,
the width of the slot portion is at least 0.35 mm. In some examples, the width
of the slot portion is
up to 3 mm, or up to 2.5 mm, or up to 2 mm, or up to 1.5 mm, or up to 1 mm, or
up to 0.8 mm, or
up to 0.7 mm, or up to 0.6 mm, or up to 0.55 mm. In some examples, the width
of the slot portion
is greater than 0.3 mm and up to 1 mm, or greater than 0.3 mm and up to 0.8
mm, or greater than
0.3 mm and up to 0.6 mm, or greater than 0.3 mm and up to 0.55 mm. In some
examples, the
width of the slot portion is between 0.25 mm and 1 mm, or between 0.25 mm and
0.8 mm, or
between 0.25 mm and 0.6 mm, or between 0.35 mm and 0.55 mm, or between 0.4 mm
and 0.5
mm.
In some examples, the width of the slit portion is up to 0.3 mm. The width of
the slit portion
is greater than 0 mm. In some examples, the slit portion has a width of up to
0.25 mm. In some
examples, the width of the slit portion is at least 0.05 mm, or at least 0.1
mm, or at least 0.15 mm.
In some examples, the width of the slit portion is between 0.05 mm and 0.3 mm,
or between 0.1
mm and 0.3 mm, or between 0.15 mm and 0.25 mm. In some examples, the width of
the slit
portion is about 0.2 mm.
It is to be understood that the join/connection between each slot portion 201
and slit
portion 200 may be of various widths intermediate of the slot portion 201 and
the slit portion 200.
The aerosol generating component 103 may comprise a plurality of curved,
elongate
apertures_ Each curved, elongate aperture may be as defined herein.
In some examples, one, more, or each curved, elongate aperture 200, 201 is
open at the
periphery of the aerosol generating component 103. As shown in Fig. 4, two of
the apertures 200,
201 are open at the periphery of the aerosol generating component 103.
In some examples, one, more, or each curved, elongate aperture 200, 201 is
enclosed by
the periphery of the aerosol generating component 103. As shown in Fig. 4, two
of the apertures
200, 201 are enclosed by the periphery of the aerosol generating component
103.
In some examples, the aerosol generating component 103 comprises an
aerosolisable
material feed section 103F configured to receive aerosolisable material (e.g.
by capillary force).
In some examples, the aerosol generating component 103 comprises an
aerosolisation
section 103G configured to aerosolise aerosolisable material.
In some examples, one, more, or each slot portion 201 is provided in the
aerosolisation
section 103G. In some examples, one, more, or each slot portion 201 does not
extend into the
aerosolisable material feed section 103F.
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In some examples, one, more, or each slit portion 200 is provided in the
aerosolisable
material feed section 103F. In some examples, one, more, or each slit portion
200 extends into
the aerosolisation section.
For example, in Fig. 4, each slot portion 201 is provided in the
aerosolisation section 103G,
two slit portions 200 are provided in the aerosolisable material feed section
103F and extend into
the aerosolisation section 103G, and two slit portions 200 are provided almost
entirely in the
aerosolisable material feed section 103F. Variations to this configuration are
envisaged.
In some examples, the aerosol generating component 103 comprises one or more
electrical connectors 103C. The aerosolisation section 103G may be provided
between electrical
connectors 103C.
The aerosol generating component 103 may comprise any other features as
defined
herein.
There is also disclosed an article 100 for use as part of a non-combustible
aerosol
provision system 10, the article 100 comprising: an aerosol generating
component 103 as defined
herein; and one or more of an aerosol forming chamber and a reservoir for
aerosolisable material.
The article 100 may be configured such that aerosolisable material can be fed
from the
reservoir to the aerosolisation section 103G via the aerosolisable material
feed section 103F.
There is also disclosed a non-combustible aerosol provision system 10
comprising: an
article 100 as defined herein; and a device 20 comprising one or more of a
power source and a
controller.
The system 10 may comprise any other features as defined herein.
According to one aspect, there is disclosed an article for use in a non-
combustible aerosol
provision system, the article comprising: a housing; and an aerosol generating
component having
at least one elongate slot, the aerosol generating component being at least
partially housed within
the housing, the housing defining a capillary gap through which aerosolisable
material can be fed
to the aerosol generating component, wherein the capillary gap and one, more,
or each elongate
slot do not overlap.
By providing the elongate slot and the capillary gap so as not to overlap, the
potential for
leakage of aerosolisable material via the elongate slot is reduced. For
example, leakage of
aerosolisable material can be more pronounced when the capillary gap coincides
with or overlaps
the elongate slot.
In some examples, one, more, or each elongate slot 201 is provided inboard of
the
capillary gap. In this way, the elongate slot 201 is provided away from the
capillary gap, towards
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the centre of the aerosol generating element 103. This configuration further
reduces the risk of
leakage of aerosolisable material.
In some examples, the capillary gap provides a capillary channel which
coincides with
and/or overlaps a periphery of the aerosol generating component 103. In some
examples, the
capillary gap provides a capillary channel which coincides with and/or
overlaps a side edge of the
aerosol generating component 103. In some examples, the capillary gap provides
two capillary
channels which coincide with and/or overlap a respective side edge of the
aerosol generating
component 103.
In some examples, one, more, or each elongate slot 201 forms part of an
elongate
aperture of the aerosol generating component 103 (in which case, the elongate
slot may be
referred to as an "elongate slot portion"). Thus, the aerosol generating
component 103 may
comprise at least one elongate aperture having at least one elongate slot 201.
In some examples, the aerosol generating component 103 comprises at least one
elongate slit 200. In some examples, one, more, or each elongate slit 200 may
form part of an
elongate aperture of the aerosol generating component 103 (in which case, the
elongate slit may
be referred to as an "elongate slit portion").
In some examples, one, more, or each elongate slot 201 is connected to an
elongate slit
200. This may be so as to form an elongate aperture 200, 201. Such a
configuration is illustrated
in Fig. 4, and is described elsewhere herein.
In some examples, one, more, or each elongate slit 200 and the capillary gap
overlap
and/or coincide. Providing an elongate slit in this location can provide
additional current path,
increase resistance and improve heating, whilst maintaining a reduced risk of
leakage via the
aerosol generating component 103.
The or each elongate slot 200 and the or each elongate slit 200 may be as
defined
elsewhere herein.
In some examples, the aerosol generating component 103 comprises an
aerosolisable
material feed section 103F configured to receive aerosolisable material (e.g.
by capillary force).
In some examples, the aerosol generating component 103 comprises an
aerosolisation
section 103G configured to aerosolise aerosolisable material. In some
examples, the aerosol
generating component 103 is substantially planar. The substantially planar
aerosol generating
component 103 may comprise multiple elongate slots 201 as defined herein.
The aerosolisable material feed section 103F and the aerosolisation section
103G may
be as described elsewhere herein.
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In some examples, one, more or each elongate slot 201 is provided in the
aerosolisation
section 103F.
In some examples, one one, more, or each elongate slit 200 is provided in the
aerosolisable material feed section 103G.
In some examples, the aerosolisation section 103G and the capillary gap do not
overlap.
In some examples, the aerosolisable material feed section 103F and the
capillary gap
overlap.
It will be appreciated that the housing may be provided in various forms. For
example, the
housing may comprise a carrier assembly. The housing, e.g. the carrier
assembly, may comprise
a first carrier component 101 and a second carrier component 102. The first
carrier component
101 and the second carried carrier component 102 may define the capillary gap.
For example,
the capillary gap may be defined by a spacing between the first carrier
component 101 and the
second carrier component 102, e.g. when the first and second carrier
components 101, 102 are
attached together. The aerosol generating component 103 may be at least
partially arranged
between the first carrier component 101 and the second carrier component 102.
The first carrier
component 101 and the second carrier component 102 may be as described
elsewhere herein.
In some examples, the aerosol generating component 103 comprises one or more
electrical connectors 1030. The aerosolisation section 103G may be provided
between electrical
connectors 1030.
The article 100 may comprise one or more of an aerosol forming chamber and a
reservoir
for aerosolisable material.
The article 100 may be configured such that aerosolisable material can be fed
from the
reservoir to the aerosolisation section 103G via the aerosolisable material
feed section 103F.
There is also disclosed a non-combustible aerosol provision system 10
comprising: an
article 100 as defined herein; and a device 20 comprising one or more of a
power source and a
controller.
The system 10 may comprise any other features as defined herein.
The Figs. herein are schematic and not drawn to scale. 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
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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.
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