JP7780646B2 - Supply System - Google Patents

Description

The present invention relates to delivery systems. In particular, the present invention relates to articles for use as part of non-combustion aerosol delivery systems, non-combustion aerosol delivery systems including the articles, and methods of making the articles.

Non-combustion aerosol delivery systems that generate aerosols for inhalation by a user are known in the art. Such systems typically include an aerosol generator capable of converting an aerosolizable material into an aerosol. In some examples, the aerosol generated is a condensation aerosol, in which the aerosolizable material is first vaporized and then allowed to condense into an aerosol. In other examples, the aerosol generated is an aerosol resulting from atomization of the aerosolizable material. Such atomization may be effected mechanically, for example, by subjecting the aerosolizable material to vibration to form small particles of the material that are entrained in an airflow. Alternatively, such atomization may be effected electrostatically or in other ways, such as using pressure.

Because such aerosol delivery systems are intended to generate an aerosol that is inhaled by the user, the characteristics of the aerosol generated must be considered. These characteristics may include the size of the aerosol particles, the total amount of aerosol generated, etc.

Controlling these various properties is particularly important when the aerosol delivery system is used to simulate the smoking experience, for example, as an e-cigarette or similar product, as users may expect a particular sensory experience to result from using the system.

It would be desirable to provide an aerosol delivery system with improved control over these properties.

According to a first aspect of the present disclosure, there is provided an article for use as part of a non-combustion aerosol delivery system, comprising a housing having a first section and a second section that together form a reservoir for aerosolizable material, the first section and the second section connected to one another to provide at least one pair of opposing surfaces, a capillary channel provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel.

One of the first section and the second section may at least partially surround the other of the first section and the second section.

One of the first section and the second section can at least partially surround the other of the first section and the second section to form a connection between the first section and the second section.

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

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

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

At least one pair of opposing surfaces may be provided by a first section and a second section.

At least one pair of opposing surfaces may be provided by the insertion portion and the receiving portion.

The first section and second section may be connected to each other by an interference fit, a press fit, a friction fit, and/or an intermediate fit.

The first section and the second section may be connected to each other so as to provide two or more pairs (e.g., two, three, four, five, or six pairs) of opposing surfaces. For example, the first surface of the first section may face the first surface of the second section, and the second surface of the first section may face the second surface of the second section, thereby providing two pairs of opposing surfaces.

One of the opposing surfaces of each pair may be provided by the receiving portion, and one of the opposing surfaces of the same pair may be provided by the insert portion.

One, multiple, or each pair of opposing surfaces may independently extend substantially axially relative to the axis of the housing. One, multiple, or each pair of opposing surfaces may independently extend substantially radially relative to the axis of the housing. One, multiple, or each pair of opposing surfaces may independently extend substantially obliquely relative to the axis of the housing. For example, one pair of opposing surfaces may extend substantially axially relative to the axis of the housing, and another pair of opposing surfaces may extend substantially radially relative to the axis of the housing.

The axis of the housing may correspond to an axis extending between the ends of the housing (e.g., between the upper and lower ends). The axis of the housing may correspond to the longitudinal axis of the housing. The axis of the housing may correspond to the axis along which the first section and the second section are connected to each other.

The opposing surfaces may have substantially the same hardness. The opposing surfaces may have a Shore A hardness of 4 to 80.

The opposing surfaces may be made from the same material.

The opposing surface may be made from a rigid material.

The opposing surface may be made from a hydrophobic material.

Non-limiting examples of suitable materials for use as the facing surface include plastic, glass, and metal. In some embodiments, the hydrophobic material is plastic. Non-limiting examples of suitable materials include nylon, polypropylene, silicone, or polycarbonate.

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

In embodiments, the article may include a dedicated sealing element to inhibit or prevent capillary flow of the aerosolizable material from the reservoir through the capillary channel. The dedicated sealing element may be a soft sealing element, such as an O-ring. The dedicated sealing element may be disposed in the capillary channel. In embodiments, the article may not include a dedicated sealing element.

At least one of the opposing surfaces may have two or more surface features.

Two or more of the opposing surfaces may have at least one surface feature.

Two or more of the opposing surfaces may have two or more surface features.

At least one surface feature may extend continuously around its respective opposing surface such that aerosolizable material cannot flow from the reservoir through the capillary channel without being obstructed by the at least one surface feature.

The at least one surface feature may comprise at least one groove. The at least one surface feature may be at least one groove. The at least one surface feature may include a hydrophobic material, for example, a hydrophobic coating.

At least one groove has a width and a depth.

At least one groove may have a width of at least 0.3 mm. At least one groove may have a width of at most 2.0 mm, or at most 1.0 mm, or at most 0.8 mm, or at most 0.6 mm.

At least one groove may have a depth of at least 0.3 mm. At least one groove may have a depth of at most 2.0 mm, or at most 1.0 mm, or at most 0.8 mm, or at most 0.6 mm.

At least one groove may be approximately or substantially annular in shape.

At least one groove may be substantially straight when viewed from the side.

At least one groove may be substantially curved when viewed from the side.

At least one groove may have a wavy shape when viewed from the side.

At least one groove may form a serpentine path when viewed from the side.

At least one groove may form a zigzag when viewed from the side.

If there are two or more grooves, the grooves may be spaced apart from each other.

When there are two or more surface features, each surface feature may independently comprise any feature described herein, including any combination of features described herein.

According to a second aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an article for use as part of the non-combustion aerosol delivery system according to the first aspect of the present disclosure, and a device comprising one or more of a power source and a controller.

According to a third aspect of the present disclosure, there is provided a method of manufacturing an article according to the first aspect of the present disclosure, comprising the steps of:
providing a housing having a first section and a second section;
connecting the first section and the second section to one another to form a reservoir for the aerosolizable material, the first section and the second section being connected to provide at least one pair of opposing surfaces;
a capillary channel is provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel;
A method is provided.

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

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

1 is a schematic diagram of an aerosol delivery system according to the present disclosure. 1 is a cross-sectional side view of an article for use as part of a non-combustion aerosol delivery system according to the present disclosure. FIG. 3 is an enlarged cross-sectional side view of a portion of the article of FIG. 2. FIG. 3 is a perspective view of a first section of the article of FIG. 2. FIG. 3 is a side view of a second section of the article of FIG. 2. FIG. 2 is a side view of an exemplary second section of an article of the present disclosure. FIG. 2 is a side view of another exemplary second section of an article of the present disclosure. FIG. 2 is a side view of another exemplary second section of an article of the present disclosure. FIG. 1 is an enlarged cross-sectional side view of a portion of an article of the present disclosure. FIG. 1 is an enlarged cross-sectional side view of an alternative article of the present disclosure. FIG. 1 is an enlarged cross-sectional side view of an alternative article of the present disclosure. FIG. 1 is an enlarged cross-sectional side view of an alternative article of the present disclosure. FIG. 1 is an enlarged cross-sectional side view of an alternative article of the present disclosure. FIG. 1 is an enlarged cross-sectional side view of an alternative article of the present disclosure.

Aspects and features of particular examples and embodiments are discussed/described herein. Some aspects and features of particular examples and embodiments may be implemented in a conventional manner and, for the sake of brevity, will not be discussed/described in detail. Accordingly, it will be understood that aspects and features of the apparatus and methods discussed herein but not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

As noted above, the present disclosure relates (without limitation) to non-combustion aerosol delivery systems and devices that generate aerosols from aerosol-generating materials (also referred to herein as aerosolizable materials) without combusting the aerosol-generating materials. Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (which generate aerosols using a combination of aerosol-generating materials). In some examples, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement of the present disclosure. In some examples, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system. In some examples, the non-combustion aerosol delivery system is a hybrid system that generates aerosols using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials in such hybrid systems may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some examples, hybrid systems include a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material may include, for example, tobacco or a non-tobacco product.

Throughout the following description, the terms "e-cigarette" and "electronic cigarette" may be used. However, it will be understood that these terms may be used interchangeably with non-combustion aerosol (vapor) delivery systems or devices such as those described above.

In some examples, the present disclosure relates to consumables for holding aerosol-generating materials and configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

A non-combustion aerosol delivery system typically includes a device portion (also referred to herein as a device) and a consumable/item portion (also referred to herein as an item). The device portion typically includes a power source and a controller. The power source may typically be a power source, such as a rechargeable battery.

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

In some examples, consumables/items for use with non-combustion aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage areas (also referred to herein as reservoirs), aerosol-generating material transfer components, aerosol generators (also referred to herein as aerosol-generating components), aerosol-generating areas (also referred to herein as chambers), housings, wrappers, filters, mouthpieces, and/or aerosol modifiers.

The systems described herein typically generate an inhalable aerosol by vaporizing an aerosol-generating material. The aerosol-generating material may include one or more active ingredients, one or more flavors, one or more aerosol-forming materials, and/or one or more other functional materials.

The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active substance and/or flavoring. In some examples, the aerosol-generating material may include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some examples, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some examples, the aerosol-generating material may include, for example, from about 50%, 60%, or 70% amorphous solid by weight, up to about 90%, 95%, or 100% amorphous solid by weight.

As used herein, the term "active substance" may refer to a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, a dietary supplement, a nootropic, or a psychoactive agent. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant.

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

The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and/or an antioxidant.

As used herein, the term "component" refers to a part, section, unit, module, assembly, or the like, of a non-combustion aerosol delivery system, such as an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly within an external housing or wall. An electronic cigarette may be formed or constructed from one or more such components, which may be removably or separably connectable to one another, or may be permanently joined to one another during manufacture to define the entire electronic cigarette. The present disclosure is applicable (but not limited to) to systems comprising two components removably connectable to one another and configured, for example, as a consumable/item component (also referred to herein as a cartridge or cartomizer) capable of holding an aerosol-generating material, and as a device/control unit having a battery for providing power to operate the elements for generating vapor from the aerosol-generating material.

1 is a highly schematic illustration (not to scale) of an exemplary non-combustion aerosol/vapor delivery system, such as an e-cigarette 10. The e-cigarette 10 may have a generally cylindrical shape extending along a longitudinal axis, indicated by the dashed line, and includes two main components: a control or power component or section 20 (also referred to as a device), and a cartridge assembly or section 30 (also referred to herein as an article, consumable, cartomizer, or cartridge), which operates as a vapor-generating component.

The cartridge assembly 30 includes a storage compartment 3 (also referred to herein as a reservoir) containing aerosolizable material, including, for example, a liquid formulation from which an aerosol is generated, e.g., containing nicotine. By way of example, the aerosolizable material may contain approximately 1-3% nicotine and 50% glycerol, with the remainder approximately propylene glycol, and possibly other ingredients such as water or flavorings. The storage compartment 3 has the form of a storage tank, a container or receptacle capable of storing the aerosolizable material such that the aerosolizable material is free to move and flow (if liquid) within the tank. Alternatively, the storage compartment 3 may contain a quantity of absorbent material, such as wadding or glass fiber, that holds the aerosolizable material within its porous structure. The storage compartment 3 may be filled and sealed during manufacture so that it is disposable after consumption, or it may have an inlet port or other opening through which new aerosolizable material can be added. The cartridge assembly 30 also includes an electrical aerosol generation component 4 disposed outside the reservoir tank 3 for generating an aerosol by vaporizing the aerosol-generating material. In many devices, the aerosol-generating component can be a heating element (heater) that is heated by the passage of an electric current (via resistive or inductive heating) to increase the temperature of the aerosolizable material until it vaporizes. A liquid conduit structure, such as a wick or other porous element (not shown), can be provided to deliver the aerosolizable material from the storage compartment 3 to the aerosol-generating component 4. The wick may have one or more portions disposed inside the storage compartment 3 that can absorb the aerosolizable material and transfer it by wicking or capillary action to another portion of the wick that contacts the vapor-generating component 4. This vaporizes the aerosolizable material and replaces it with new aerosolizable material transferred by the wick to the vapor-generating component 4.

The combination of a heater and wick, or other arrangement of components that perform the same function, may be referred to as an atomizer or atomizer assembly. Various designs are possible in which the components may be arranged differently compared to the highly schematic illustration of Figure 1. For example, the wick may be an entirely separate element from the aerosol generation component, or the aerosol generation component may be configured to be porous and capable of directly performing the wicking function (e.g., by taking the form of a suitable electrically resistive mesh or capillary body).

In some cases, the conduit for delivering liquid for vapor 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 that are narrow enough to assist capillary action in drawing source liquid from the storage compartment and providing it for vaporization. In general, an atomizer can be thought of as an aerosol-generating component capable of generating vapor from an aerosolizable material delivered to it, and a liquid conduit (pathway) capable of delivering or transporting liquid from the storage compartment or similar liquid reservoir to the aerosol-generating component by capillary forces.

Typically, the aerosol-generating components are disposed at least partially within an aerosol-generating chamber that forms part of the airflow channel through the electronic cigarette/system. Vapor generated by the aerosol-generating components is forced into this chamber, and as air flows through the chamber and over and around the aerosol-generating elements, the aerosol-generating elements collect and condense the generated vapor 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 can inhale the aerosol generated by the aerosol generating component 4 and delivered through the airflow channel.

The power component 20 includes a cell or battery 5 (hereinafter also referred to as a battery, which may be rechargeable) for powering the electrical components of the e-cigarette 10, particularly the aerosol-generating component 4. Additionally, there is a printed circuit board 28 and/or other electronics or circuitry for overall control of the e-cigarette. The control electronics/circuitry connects the vapor-generating component 4 to the battery 5 when vapor is needed, for example, in response to a signal from an air pressure or airflow sensor (not shown) that detects inhalation on the system 10, where air enters through one or more air inlets 26 in the wall of the power component 20 to flow along an airflow channel. When the aerosol-generating component 4 receives power from the battery 5, it vaporizes the aerosolizable material delivered from the storage compartment 3 to generate an aerosol, which is then inhaled by the user through an opening in the mouthpiece 35. The aerosol is transported to the mouthpiece 35 along the airflow channel (not shown) connecting the air inlet 26 to the air outlet when the user inhales on the mouthpiece 35. Thus, an airflow path through the electronic cigarette is defined between the air inlet to the atomizer (which may or may not be in the power component) and the air outlet at the mouthpiece. In use, the airflow direction along this airflow path is from the air inlet to the air outlet, and therefore the atomizer can be described as being downstream of the air inlet and upstream of the air outlet.

In this particular example, the power section 20 and cartridge assembly 30 are separate parts that can be separated from one another by separating them in a direction parallel to the longitudinal axis, as shown by the solid arrows in FIG. 1 . The components 20, 30 are joined together by cooperating engaging elements 21, 31 (e.g., threaded, magnetic, or bayonet fittings) that provide a mechanical and electrical connection between the power section 20 and cartridge assembly 30 when the device 10 is in use. However, this is merely an exemplary arrangement, and various components may be distributed differently between the power section 20 and cartridge assembly section 30, and other components and elements may be included. The two sections may be connected to one another end-to-end in a longitudinal configuration, as shown in FIG. 1 , or may be connected in a different configuration, such as a parallel side-by-side arrangement. The system may or may not be generally cylindrical and/or may have a generally longitudinal shape. Either or both sections may be intended to be disposed of and replaced when depleted (e.g., when the reservoir is empty or the battery is dead), or may be intended to allow multiple uses by actions such as refilling the reservoir, recharging the battery, or replacing the atomizer. 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 contained within a single body or housing. Embodiments and examples of the present invention are applicable to any of these and other configurations as will be recognized by those skilled in the art.

As mentioned above, types of aerosol-generating components, such as heating elements, that may be utilized in the atomizing portion of an electronic cigarette (the portion configured to generate vapor from a source liquid) combine the functions of heating and liquid delivery by being both electrically conductive (electrically resistive) and porous. Note that reference to being electrically conductive (electrically resistive) refers to a component capable of generating heat in response to the flow of electrical current therethrough. Such flow can be imparted via so-called resistive or inductive heating. One example of a suitable material for this purpose is a conductive material, such as a metal or metal alloy, formed in sheet form, i.e., a planar shape having a thickness many times smaller than its length or width. Examples of this can be meshes, webs, grills, and the like. Meshes may be formed from metal wires or fibers woven together, or may be aggregated into a nonwoven structure. For example, fibers may be aggregated by sintering, in which heat and/or pressure is applied to a collection of metal fibers to compress them into a single porous mass.

These structures can provide appropriately sized voids and gaps between the metal fibers to create capillary forces for the wicking of liquids. Therefore, these structures can also be considered porous, as they allow for liquid uptake and distribution. Furthermore, the presence of voids and gaps between the metal fibers allows air to permeate through the structure. Metals are also electrically conductive and therefore suitable for resistive heating, whereby an electric current passing through a material with electrical resistance generates heat. However, this type of structure is not limited to metals; other electrically conductive materials may be formed into fibers and mesh, grill, or web structures. Examples include ceramic materials that may or may not be doped with substances intended to adjust the physical properties of the mesh.

This type of planar sheet-like porous aerosol-generating component can be positioned within an electronic cigarette within an aerosol-generating chamber that forms part of the airflow channel. The aerosol-generating component can be oriented within the chamber so that airflow through the chamber flows 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 WO 2010/045670 and WO 2010/045671, the contents of which are incorporated herein by reference in their entirety. Air can thus flow over the heating element and collect vapor, resulting in highly effective aerosol generation. In an alternative example, the aerosol-generating component can be oriented within the chamber so that airflow through the chamber flows in a direction substantially transverse to the surface direction, i.e., substantially perpendicular to the plane of the generally planar sheet-like aerosol-generating component. An example of such a configuration can be found in WO 2018/211252, the contents of which are incorporated herein by reference in their entirety.

The aerosol-generating component may have any one of the following structures: woven, mesh, fabric, open-pore fiber, open-pore sintered, foam, or stacked structure. These structures are particularly suitable for providing aerosol-generating components with a high degree of porosity. This high degree of porosity ensures that the heat generated by the aerosol-generating component is primarily used to evaporate the liquid, resulting in high efficiency. Porosities of more than 50% may be achieved by these structures. In one embodiment, the porosity of the aerosol-generating component is 50% or more, 60% or more, or 70% or more. Open-pore fiber structures may, for example, consist of nonwoven fabrics, which may optionally be compressed and further sintered to improve cohesion. Open-pore sintered structures may, for example, consist of granular, fibrous, or cotton-like sintered composites produced by film casting. Open-pore stacked structures may, for example, be produced by CVD, PVD, or flame spraying. Open-pore foams are, in principle, commercially available and can even be obtained with thin pore designs.

In one embodiment, the aerosol-generating component has at least two layers, each of which comprises at least one of the following structures: plate, foil, paper, mesh, woven structure, fabric, open-pore fiber structure, open-pore sintered structure, open-pore foam, or open-pore stack structure. For example, the aerosol-generating component can be formed by an electrical heating resistor consisting of a metal foil combined with a structure containing a capillary structure. When the aerosol-generating component is considered to be formed from a single layer, such a layer can be formed from a woven metal wire fabric or a nonwoven metal fiber fabric. The individual layers are preferably, but not necessarily, connected to each other 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 woven stainless steel wire fabric (materials such as AISI 304 or AISI 316). Alternatively, the aerosol-generating component can be designed as a sintered composite consisting of at least two layers of woven stainless steel wire fabric. The layers can be connected to each other by spot welding or resistance welding. The individual layers may also be mechanically connected to one another. For example, a double-layer wire fabric can be produced by simply folding a single layer. Instead of stainless steel, for example, a heating conductor alloy, particularly a NiCr alloy or a CrFeAl alloy called "Kanthal," which has an even higher specific electrical resistance than stainless steel, can also be used. The material connection between the layers is achieved by heat treatment, so that the layers remain in contact with one another even under adverse conditions, such as during heating by the aerosol-generating component and the resulting induced thermal expansion. Alternatively, the aerosol-generating component may be formed by sintering multiple individual fibers together. Thus, the aerosol-generating component may be composed of sintered fibers, such as sintered metal fibers.

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

As mentioned above, the aerosol-generating component may be formed from a sintered metal fiber material, which may be in the form of a sheet. This type of material can be thought of as a mesh or irregular grid, created by sintering together a randomly aligned arrangement or array of spaced apart metal fibers or strands. A single layer of fibers, or several layers, e.g., up to five layers, may be used. By way of example, the metal fibers may have a diameter of 8-12 μm, be arranged to provide a sheet 0.16 mm thick, and be spaced to produce a material density ^of 100 g/m ^to 1500 g/m, e.g., 150 g/ ^{m to} 1000 g/m, 200 g/ ^m to 500 g/ ^m , or 200-250 g/m, and a porosity ^of 84%. The sheet thickness may also be in the range of 0.1 mm to 0.2 mm, e.g., 0.1 mm to 0.15 mm. Specific thicknesses include 0.10 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, or 0.1 mm. Generally, the aerosol-generating component has a uniform thickness. However, it will be understood from the following description that the thickness of the aerosol-generating component may vary. This may be due, for example, to portions of the aerosol-generating component being subjected to compression. Different fiber diameters and thicknesses can be selected to vary the porosity of the aerosol-generating component. For example, the aerosol-generating component may have a porosity of 66% or more, or 70% or more, or 75% or more, or 80% or more, or 85% or more, or 86% or more.

The aerosol-generating component may form a generally planar structure including a first and second surface. The generally planar structure may take the form of any two-dimensional shape, for example, a circle, semicircle, triangle, square, rectangle, and/or polygon. Generally, the aerosol-generating component has a uniform thickness.

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

If the aerosol-generating component is formed from an electrically resistive material, an electric current can flow through the aerosol-generating component 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, e.g., 1.8 ohms or less, e.g., 1.7 ohms or less, e.g., 1.6 ohms or less, e.g., 1.5 ohms or less, e.g., 1.4 ohms or less, e.g., 1.3 ohms or less, e.g., 1.2 ohms or less, e.g., 1.1 ohms or less, e.g., 1.0 ohms or less, e.g., 0.9 ohms or less, e.g., 0.8 ohms or less, e.g., 0.7 ohms or less, e.g., 0.6 ohms or less, e.g., 0.5 ohms or less. Parameters of the aerosol-generating component, such as the material, thickness, width, length, and porosity, can be selected to provide the desired resistance. In this regard, a relatively low resistance facilitates higher power draw from the power source, which may be preferable for achieving high-rate aerosolization. On the other hand, the resistance should not be so low that it compromises the integrity of the aerosol generator. For example, the resistance should not be lower than 0.5 ohms.

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

Figures 2-5 show an exemplary article (or consumable) 100 for use as part of a non-combustion aerosol delivery system 10 according to the present disclosure.

The article 100 comprises a housing 101 having a first section 102 and a second section 103. The first section 102 and the second section 103 together form a reservoir 104 for the aerosolizable material 200. The first section 102 and the second section 103 are connected to one another to provide at least one pair of opposing surfaces 106, 108 and 107, 109. A capillary channel 110 is provided between at least one of the opposing surfaces 106, 108 and 107, 109. Typically, the capillary channel 110 is an artifact of the process for manufacturing the article 100. That is, manufacturing tolerances result in the capillary channel 110 being provided between the opposing surfaces 106, 108 and 107, 109. In use, the aerosolizable material 200 in the reservoir 104 may leak through the capillary channel 110, where it is drawn through the capillary channel 110 by capillary forces. Those skilled in the art will understand that a capillary channel is a channel through which liquid aerosolizable material can be drawn by capillary forces at the surface of the channel.

Capillary leakage is undesirable for a number of reasons. For example, leaked aerosolizable material 200 can be inconvenient and/or uncomfortable, thereby negatively impacting the user experience. Also, leaked aerosolizable material 200 is wasted. Furthermore, leaked aerosolizable material 200 can affect the performance of system 10 and/or cause the user to perceive system 10 as malfunctioning.

In the article 100 of the present invention, at least one of the facing surfaces 106-109 includes at least one surface feature 111 for inhibiting or preventing capillary flow of the aerosolizable material 200 from the reservoir 104 through the capillary channel 110. The surface feature 111 obstructs the capillary flow of the aerosolizable material 200 through the capillary channel 110, thereby inhibiting or preventing capillary leakage of the aerosolizable material 200 from the reservoir 104 via the capillary channel 110. The aerosolizable material 200 is partially or completely prevented from flowing from the reservoir 104 into the at least one surface feature 111.

In this particular embodiment, each surface feature 111 is a groove. The use of grooves has been found to be particularly effective in reducing or preventing leakage through the capillary channel. Without being bound by theory, it is believed that the at least one groove provides additional separation between the opposing surfaces such that capillary forces cannot be maintained, thus reducing or preventing aerosolizable material from being drawn through the channel. Furthermore, capillary forces of the opposing surfaces 106-109 are believed to retain the aerosolizable material 200 within the capillary channel 110 upstream of the at least one groove 111 (as shown in FIG. 3).

Due to the sealing effect of the at least one surface feature 111, a dedicated (e.g., separate and/or non-integral) sealing element, such as an O-ring, may not be necessary to inhibit or prevent capillary flow of the aerosolizable material 200 from the reservoir 104 through the capillary channel 110. Accordingly, the article 100 of the present invention can be manufactured without such a dedicated sealing element. In fact, the at least one surface feature 111 may be the only means for inhibiting or preventing capillary flow of the aerosolizable material 200 from the reservoir 104 through the capillary channel 110. Accordingly, the article 100 of the present invention may be more cost-effective to manufacture than prior art articles because the material costs of providing a dedicated sealing element can be avoided. Furthermore, the article 100 of the present invention may be easier to manufacture than prior art articles because the step of assembling a dedicated sealing element within the article can be avoided. Furthermore, the article 100 of the present invention may be more reliable than prior art articles because the risk of degradation, malfunction, and/or failure of a dedicated sealing element can be avoided. These issues are particularly relevant for articles having soft seals, such as O-rings, which can be subject to manufacturing imperfections and can degrade over time due to, for example, exposure to certain chemicals and/or certain environmental conditions. Furthermore, even without the inclusion of a dedicated sealing element such as an O-ring, it is possible to form each portion of the housing from similar materials while still limiting or preventing leakage of the aerosolizable material, thereby simplifying manufacturing.

2, the housing 101 is generally cylindrical in shape and has an upper end (opposite the second section 103) and a lower end (at the second section 103). The housing 101 has a longitudinal axis extending between its upper and lower ends. However, those skilled in the art will appreciate that the housing 101 and its first and second sections 102, 103 may be provided in a variety of different shapes. For example, the housing 101 may be generally polygonal in shape, such as a generally rectangular prism in shape. For example, the housing 101 may be generally plate-like in shape. For example, the housing 101 may be tapered toward one or both ends.

2, the first section 102 is generally cylindrical in shape. The first section 102 has a receiving portion 112 in the form of an end that defines an opening to the space. The exact shape of the receiving portion 112 may be varied. The first section 102 also has an opposite end that is closed. The second section 103 is generally plate-like in shape. The second section 103 has an insert portion 113 that is inserted into the receiving portion 112. The second section 103 has an abutment portion 114 that extends radially from the insert portion 113. The abutment portion 114 abuts the receiving portion 112. Thus, the reservoir 104 corresponds to the space enclosed by the first section 102 and the second section 103. As noted above, the exact shape and arrangement of the first section 102 and the second section 103 may be varied. For example, in some embodiments, the abutment portion 114 is optional.

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

One, several, or each pair of opposing surfaces 106, 108 and 107, 109 may independently extend substantially axially, substantially radially, or substantially obliquely relative to the axis of the housing 101. The axis of the housing 101 may be an axis extending between the ends of the housing 101 (i.e., between the upper and lower ends). The axis of the housing 101 may be the longitudinal axis of the housing 101. The axis of the housing 101 may be the axis along which the first section 102 and the second section 103 are connected to each other (as described below).

2, one pair of opposing surfaces 106, 108 extend substantially axially relative to the longitudinal axis of the housing 101, and another pair of opposing surfaces 107, 109 extend substantially radially relative to the longitudinal axis of the housing. Thus, the axial opposing surfaces 106, 108 are substantially perpendicular to the radial opposing surfaces 107, 109. As described above, capillary channels 110 are provided between the opposing surfaces 106, 108 and between the opposing surfaces 107, 109.

Those skilled in the art will understand that the capillary channel 110 is shown schematically in the figures. For example, the first section 102 and the second section 103 are connected to one another such that portions of the opposing surfaces 106-109 contact one another, while other portions of the opposing surfaces 106-109 are spaced apart to form the capillary channel 110. Because manufactured articles are not identical, at least in part due to manufacturing tolerances, the exact shape of the capillary channel 110 may vary from article to article. Those skilled in the art will understand that the opposing surfaces 106-109 may be provided in a variety of different shapes, which may vary depending on the shape of the first section 102 and the second section 103.

In the embodiment of FIG. 2, at least one of the facing surfaces 106-109 includes two or more surface features 111 to inhibit or prevent capillary flow of aerosolizable material from the reservoir through the capillary channel. In some embodiments, there may be one surface feature 111 (as shown in FIGS. 7 and 8). In some embodiments, two or more of the facing surfaces 106-109 include at least one surface feature 111 to inhibit or prevent capillary flow of aerosolizable material from the reservoir through the capillary channel (as shown in FIG. 12).

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

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

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

When there are two or more pairs of opposing surfaces 106, 108 and 107, 109, at least one of the opposing surfaces in each pair may include at least one surface feature 111 (as shown in FIGS. 13 and 14). In FIG. 13, the (axial) opposing surface 108 of the second section 103 includes at least one surface feature 111, and the (radial) opposing surface 109 of the second section 103 includes at least one surface feature 111. In FIG. 14, the (axial) opposing surface 106 of the first section 102 includes at least one surface feature 111, and the (radial) opposing surface 107 of the first section 102 includes at least one surface feature 111.

2, the surface features 111 are spaced apart from one another, and each surface feature 111 is substantially annular in configuration. Each surface feature 111 extends continuously around its respective opposing surface 106-109 such that aerosolizable material 200 cannot flow from the reservoir 104 through the capillary channel 110 without being obstructed by at least one surface feature 111. This configuration is effective to prevent capillary leakage of aerosolizable material from the reservoir. More specifically, each surface feature 111 extends continuously around the (axially) opposing surface 108 of the second section such that aerosolizable material 200 cannot flow from the reservoir 104 through the capillary channel 110 without being obstructed by at least one surface feature 111.

In some embodiments, at least one surface feature 111 may extend partially around its respective opposing surface 106-109. Such embodiments may include multiple surface features 111. Multiple surface features 111 may together provide effective sealing performance.

At least one groove 111 may have a depth of at least 0.3 mm. At least one groove 111 may have a width of at least 0.3 mm. Such dimensions have been found to provide particularly effective sealing performance. At least one groove 111 may have a width of at most 2.0 mm, or at most 1.0 mm, or at most 0.8 mm, or at most 0.6 mm. At least one groove 111 may have a depth of at most 2.0 mm, or at most 1.0 mm, or at most 0.8 mm, or at most 0.6 mm.

Those skilled in the art will appreciate that the groove 111 may be provided in a variety of shapes and dimensions. For example, the groove 111 may or may not be generally annular in shape.

In an embodiment, one of the first section 102 and the second section 103 at least partially surrounds the other of the first section 102 and the second section 103 (see, for example, FIG. 2). One of the first section 102 and the second section 103 can at least partially surround the other of the first section 102 and the second section 103 to form a connection between the first section 102 and the second section 103. For example, one of the first section 102 and the second section 103 can at least partially surround the other of the first section 102 and the second section 103 to provide at least one pair of opposing surfaces 106, 108. Thus, one of the first section 102 and the second section 103 can be at least partially inserted into the other of the first section 102 and the second section 103. It will be understood that other arrangements are also contemplated.

The first section 102 and the second section 103 may be connected to one another by an engineered fit. For example, the first section 102 and the second section 103 may be connected to one another by an interference fit, a press fit, a friction fit, and/or an intermediate fit. These fits can provide a secure connection and simplify the manufacture of the article 100.

In an embodiment, one of the first section 102 and the second section 103 at least partially surrounds the other of the first section 102 and the second section 103 to form a connection between the first section 102 and the second section 103, the connection being one or more of an interference fit, a press fit, a friction fit, and/or an intermediate fit. With this arrangement, a simple and secure connection may be formed between the first section 102 and the second section 103. Therefore, separate fastening means (e.g., screws and pins) for connecting the first section 102 and the second section 103 to each other may not be necessary, as fewer components may be required that have the potential for failure.

In the embodiment of FIG. 2, the receiving portion 112 surrounds the insert portion 113 to provide an interference fit, press fit, friction fit, and/or transition fit between the first section 102 and the second section 103. Those skilled in the art are familiar with how to provide such types of engineered fits by sizing the first section 102 and the second section 103 accordingly. In some embodiments, the opposing surfaces 106-109 may have substantially the same hardness. The opposing surfaces 106-109 may have a Shore A hardness of 4 to 80. In the context of the present invention, hardness is measured using the Shore A scale. Such hardness has been found to provide surface features 111 that are particularly effective at sealing against capillary leakage.

The opposing surfaces 106-109 may be made from the same material. The advantage of this is that manufacturing of the article may be simplified.

The opposing surfaces 106-109 may be made from a rigid material. This has been found to result in a robust article that is particularly effective at sealing against capillary leakage.

The opposing surfaces 106-109 may be made from or treated with a hydrophobic material. The hydrophobic material can help to reduce or prevent the movement of the aerosolizable material by capillary action, and thus reduce or prevent capillary leakage through the capillary channel.

Non-limiting examples of suitable materials for use as opposing surfaces 106-109 include plastic, glass, and metal. Non-limiting examples of suitable materials include nylon, polypropylene, silicone, or polycarbonate. The first section 102 may be formed from any of the materials disclosed herein. The second section 102 may be formed from any of the materials disclosed herein.

Manufacture of article 100 will now be described by way of non-limiting example. The first and second sections 102, 103 of housing 101 can be provided by any suitable technique, such as injection molding. The first and second sections 102, 103 are connected to one another to form a reservoir 104 for aerosolizable material 200, and the first and second sections 102, 103 are connected to one another to provide at least one pair of opposing surfaces 106, 108 and 107, 109. Due to manufacturing tolerances between the first and second sections 102, 103, capillary channels 110 are provided between the opposing surfaces 106, 108 and 107, 109. At least one of the opposing surfaces 106-109 includes at least one surface feature 111 for inhibiting or preventing capillary flow of aerosolizable material 200 from the reservoir 104 through the capillary channel 110.

To connect the first section 102 and the second section 103 to each other, the first section 102 and the second section 103 may be pressed against each other. This allows at least a portion of one of the first section 102 and the second section 103 to be inserted into the other of the first section 102 and the second section 103 (depending on the respective shapes of the first section 102 and the second section 103). In other words, this allows one of the first section 102 and the second section 103 to at least partially surround the other of the first section 102 and the second section 103.

In the embodiment of FIG. 2, the insert portion 113 is inserted through the opening 112 such that the abutment portion 114 abuts the end of the first section 102 that defines the opening 112. Due to the respective sizing of the first section 102 and the second section 103, the insertion results in a secure connection between the first section 102 and the second section 103. The connection may be by an engineered fit, such as an interference fit, press fit, friction fit, and/or transition fit.

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

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

The drawings presented herein are schematic and not drawn to scale. The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not intended to be exhaustive and/or exclusive. The advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or equivalents thereof, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims (19)

a housing having a first section and a second section that together form a reservoir for an aerosolizable material, the first section and the second section being connected to one another to provide at least one pair of opposing surfaces;
a capillary channel is provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel , the at least one surface feature being at least one groove;
An article for use as part of a non-combustion aerosol delivery system. The article of claim 1, wherein one of the first section and the second section at least partially surrounds the other of the first section and the second section. The article of claim 1 or 2, wherein the first section and the second section are connected to each other by an interference fit, a press fit, a friction fit, and/or an intermediate fit. The article of claim 1 or 2, which does not include a sealing element dedicated to inhibiting or preventing capillary flow of aerosolizable material from the reservoir through the capillary channel. The article of claim 1 or 2, wherein at least one of the opposing surfaces comprises two or more surface features for preventing capillary flow of aerosolizable material from the reservoir through the capillary channel. The article of claim 1 or 2, wherein at least one surface feature extends continuously around each opposing surface of the surface feature such that aerosolizable material cannot flow from the reservoir through the capillary channel without being obstructed by the at least one surface feature. 3. The article of claim 1 or 2 , wherein the at least one groove has a width of at least 0.3 mm. 3. The article of claim 1 or 2 , wherein the at least one groove has a depth of at least 0.3 mm. 3. The article of claim 1 or 2 , wherein at least one groove is generally or substantially annular in configuration. 3. The article of claim 1 or 2 , wherein at least one groove is substantially straight in side view. 3. The article of claim 1 or 2 , wherein at least one groove is substantially curved in side view. 3. The article of claim 1 or 2 , wherein at least one groove has a wavy configuration when viewed from the side. 3. The article of claim 1 or 2 , wherein at least one groove forms a tortuous path in a side view. The article of claim 1 or 2 , wherein the at least one groove forms a zigzag in a side view. 3. The article of claim 1 , wherein the opposing surfaces have substantially the same hardness. 3. The article of claim 1 , wherein the opposing surface has a Shore A hardness of 4 to 80. The article of claim 1 or 2 , wherein the aerosolizable material is an aerosolizable liquid. 1. A non-combustion aerosol delivery system comprising:
3. The article of claim 1 or 2 for use as part of the non-combustion aerosol delivery system;
a device comprising one or more of a power source and a controller. A method for producing the article of claim 1 or 2 , comprising the steps of:
providing a housing having a first section and a second section;
connecting the first section and the second section to one another to form a reservoir for an aerosolizable material, the first section and the second section being connected to one another to provide at least one pair of opposing surfaces;
a capillary channel is provided between the opposing surfaces, at least one of the opposing surfaces comprising at least one surface feature for inhibiting or preventing capillary flow of the aerosolizable material from the reservoir through the capillary channel , the at least one surface feature being at least one groove;
method.