PROVISION SYSTTEM

FIELD

The present invention relates to a provision system. In particular, the present invention relates to an article for use as part of a non-combustible aerosol provision system, to a non-combustible aerosol provision system comprising the article, and a method of manufacturing the article.

BACKGROUND

Non-combustible aerosol provision systems that generate an aerosol for inhalation by a user are known in the art. Such systems typically comprise an aerosol generator that is capable of converting an aerosolizable material into an aerosol. In some instances, the aerosol generated is a condensation aerosol whereby an aerosolizable material is first vaporized and subsequently allowed to condense into an aerosol. In other instances, the aerosol generated is an aerosol that results from the atomization of the aerosolizable material. Such atomization may be brought about mechanically, e.g. by subjecting the aerosolizable material to vibrations to form small particles of material that are entrained in airflow. Alternatively, such atomization may be brought about electrostatically, or in other ways, such as by using pressure etc.

Since such aerosol delivery 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 delivery 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 article for use as part of a non-combustible aerosol provision system, the article comprising: a housing having a first section and a second section which together form a reservoir for an aerosolizable material, the first section and the second section being connected together to provide at least one pair of opposing surfaces; wherein a capillary channel is provided between the opposing surfaces, and at least one of the opposing surfaces comprises at least one surface feature for inhibiting or preventing capillary flow of an 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 may at least partially surround the other of the first section and the second section to form the 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 the 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 comprise an insertion portion and the other of the first section and the second section may comprise a receiving portion. The insertion portion may be inserted into the receiving portion.

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

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

The first section and the second section may be connected together by an interference fit, a press fit, a friction fit, and/or a transition fit.

The first section and the second section may be connected together to provide more than one (e.g. two, three, four, five or six) pair of opposing surfaces. For example, a first surface of the first section and a first surface of the second section may be opposing, and a second surface of the first section and a second surface of the second section may be opposing, thereby to provide two pairs of opposing surfaces.

An opposing surface of each pair of opposing surfaces may be provided by the receiving portion, and an opposing surface of the same pair of opposing surfaces may be provided by the insertion portion.

One, more or each pair of opposing surfaces may independently extend substantially axially with respect to an axis of the housing. One, more or each pair of opposing surfaces may independently extend substantially radially with respect to an axis of the housing. One, more or each pair of opposing surfaces may independently extend substantially angularly with respect to an axis of the housing. For example, one pair of opposing surfaces may extend substantially axially with respect to the axis of the housing, and another pair of opposing surfaces may extend substantially radially with respect to the axial of the housing.

The axis of the housing may correspond to the axis extending between ends (e.g. top and bottom) of the housing. 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 together.

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

The opposing surfaces may be made of the same material.

The opposing surfaces may be made of a rigid material.

The opposing surfaces may be made of a hydrophobic material.

Non-limiting examples of suitable materials for use as the opposing surfaces 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 an aerosolizable material from the reservoir through the capillary channel.

In embodiments, the article may comprise a dedicated sealing element for inhibiting or preventing capillary flow of an 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 provided in the capillary channel. In embodiments, the article may not comprise the dedicated sealing element.

At least one of the opposing surfaces may comprise more than one surface feature.

More than one of the opposing surfaces may comprise at least one surface feature.

More than one of the opposing surfaces may comprise more than one surface feature.

The 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 intercepted 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 comprise a hydrophobic material, e.g. a hydrophobic coating.

The at least one groove has a width and a depth.

The at least one groove may have a width of at least 0.3 mm. The at least one groove may have a width of up to 2.0 mm, or up to 1.0 mm, or up to 0.8 mm, or up to 0.6 mm.

The at least one groove may have a depth of at least 0.3 mm. The at least one groove may have a depth of up to 2.0 mm, or up to 1.0 mm, or up to 0.8 mm, or up to 0.6 mm.

The at least one groove may be of a generally or substantially annular form.

The at least one groove may be substantially straight when viewed side-on.

The at least one groove may be substantially curved when viewed side-on.

The at least one groove may be of an undulating form when viewed side-on.

The at least one groove may form a tortuous path when viewed side-on.

The at least one groove may form a zig-zag when viewed side-on.

Where there is more than one groove, the grooves may be spaced apart from each other.

Where there is more than one surface feature, each surface feature may independently comprise any features as described herein, including any combination of the features as described herein.

According to a second aspect of the present disclosure, there is provided a non-combustible aerosol provision system comprising: an article for use as part of the non-combustible aerosol provision system according to the first aspect of the present disclosure; and 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, the method comprising:

- providing a housing having a first section and a second section; and
- connecting the first section and the second section together to form a reservoir for an aerosolizable material, the first section and the second section being connected to provide at least one pair of opposing surfaces;

wherein a capillary channel is provided between the opposing surfaces, and at least one of the opposing surfaces comprises at least one surface feature for inhibiting or preventing capillary flow of an aerosolizable material from the reservoir through the capillary channel.

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:

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

FIG. 2 is a cross-sectional side view of an article for use as part of a non-combustible aerosol provision system according to the present disclosure.

FIG. 3 is a close-up cross-sectional side view of part of the article of FIG. 2.

FIG. 4 is perspective view of the first section of the article of FIG. 2.

FIG. 5 is a side view of the second section of the article of FIG. 2.

FIG. 6 is a side view of an exemplary second section of an article of the present disclosure.

FIG. 7 is a side view of another exemplary second section of an article of the present disclosure.

FIG. 8 is a side view of another exemplary second section of an article of the present disclosure.

FIG. 9 is a close-up cross-sectional side view of part of an article of the present disclosure.

FIG. 10 is a close-up cross-sectional side view of an alternative article of the present disclosure.

FIG. 11 is a close-up cross-sectional side view of an alternative article of the present disclosure.

FIG. 12 is a close-up cross-sectional side view of an alternative article of the present disclosure.

FIG. 13 is a close-up cross-sectional side view of an alternative article of the present disclosure.

FIG. 14 is a close-up cross-sectional side view of an alternative article of the present disclosure.

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 to (but is not limited to) non-combustible aerosol provision systems and devices that generate an aerosol from an aerosol-generating material (which also may be referred to herein as aerosolizable 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 (vapor) 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 provision devices. These consumables are sometimes referred to as articles throughout the present disclosure.

The non-combustible aerosol provision system typically comprises a device part (which also may be referred to herein as a device) and a consumable/article part (which also may be 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 (which also may be referred to herein as a reservoir), an aerosol-generating material transfer component, an aerosol generator (which also may be referred to herein as an aerosol generating component), an aerosol generation area (which also may be referred to herein as a 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 vaporization of an aerosol generating material. The aerosol generating material may comprise one or more active constituents, one or more flavors, 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 flavorants. 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 50 wt %, 60 wt % or 70 wt % of amorphous solid, to about 90 wt %, 95 wt % or 100 wt % 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, 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, coloring 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 a non-combustible aerosol provision system such as 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 cartomizer), and a device/control unit having a battery for providing electrical power to operate an element for generating vapor from the aerosol generating material.

FIG. 1 is a highly schematic diagram (not to scale) of an example non-combustible aerosol/vapor provision system such as an e-cigarette 10. The e-cigarette 10 may have 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 also may be referred to as a device) and a cartridge assembly or section 30 (which also may be referred to herein as an article, consumable, cartomizer, or cartridge) that operates as a vapor generating component.

The cartridge assembly 30 includes a storage compartment (which may also be referred to herein as a reservoir) 3 containing an aerosolizable material comprising (for example) a liquid formulation from which an aerosol is to be generated, for example containing nicotine. As an example, the aerosolizable 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 flavorings. The storage compartment 3 has the form of a storage tank, being a container or receptacle in which aerosolizable material can be stored such that the aerosolizable material is free to move and flow (if liquid) within the confines of the tank. Alternatively, the storage compartment 3 may contain a quantity of absorbent material such as cotton wadding or glass fiber which holds the aerosolizable material within a porous structure. The storage compartment 3 may be sealed after filling during manufacture so as to be disposable after the aerosolizable material is consumed, or may have an inlet port or other opening through which new aerosolizable 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 vaporization of the aerosolizable material. In many devices, 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 aerosolizable material until it evaporates. A liquid conduit arrangement such as a wick or other porous element (not shown) may be provided to deliver aerosolizable 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 aerosolizable material and transfer it by wicking or capillary action to other parts of the wick that are in contact with the vapor generating element 4. This aerosolizable material is thereby vaporized, to be replaced by new aerosolizable material transferred to the vapor generating element 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 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 which are narrow enough to support capillary action to draw source liquid out of the storage compartment and deliver it for vaporization. In general, an atomiser can be considered to be an aerosol generating component able to generate vapor from aerosolizable 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.

Typically, the aerosol generating component is at least partly located within an aerosol generating chamber that forms part of an airflow channel through the electronic cigarette/system. Vapor 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 vapor 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 or battery 5 (which also may be referred to herein after 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 vapor generating element 4 to the battery 5 when vapor 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 vaporizes aerosolizable 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 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. Embodiments and 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 utilized in an atomising portion of an electronic cigarette (a part configured to generate vapor 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 fibers which are woven together, or alternatively aggregated into a non-woven structure. For example, fibers may be aggregated by sintering, in which heat and/or pressure are applied to a collection of metal fibers to compact them into a single porous mass.

These structures can give appropriately sized voids and interstices between the metal fibers 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 fibers, 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; other conductive materials may be formed into fibers and made into mesh, grill or web structures. Examples include 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 WO2010/045670 and WO2010/045671, the contents of which are incorporated herein in their entirety by reference. Air can thence flow over the heating element, and gather vapor. 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 WO2018/211252, the contents of which are incorporated herein in its entirety by reference.

The aerosol generating component may have 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 a 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 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-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. This, 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 to 12 μm, arranged to give a sheet of thickness 0.16 mm, and spaced to produce a material density of from 100 g/m²to 1500 g/m², such as from 150 g/m²to 1000 g/m², 200 g/m²to 500 g/m², or 200 to 250 g/m², and a porosity of 84%. The sheet thickness may also range from 0.1 mm to 0.2 mm, such as 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 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 50 mm. 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.

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 1.8 ohms or less, such as 1.7 ohms or less, such as 1.6 ohms or less, such as 1.5 ohms or less, such as 1.4 ohms or less, such as 1.3 ohms or less, such as 1.2 ohms or less, such as 1.1 ohms or less, such as 1.0 ohm or less, such as 0.9 ohms or less, such as 0.8 ohms or less, such as 0.7 ohms or less, such as 0.6 ohms or less, such as 0.5 ohms or less. 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 aerosolization. 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.

FIGS. 2 to 5 show an exemplary article (or consumable) 100 for use as part of a non-combustible aerosol provision 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 aerosolizable material 200. The first section 102 and the second section 103 are connected together 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 artefact of the process to manufacture the article 100. That is, manufacturing tolerances result in the provision of a capillary channel 110 between the opposing surfaces 106, 108 and 107, 109. In use, aerosolizable material 200 in the reservoir 104 can leak through the capillary channel 110, whereby it is drawn through the capillary channel 110 by capillary force. The skilled person will appreciate that a capillary channel is a channel through which a liquid aerosolizable material can be drawn by capillary force of the surfaces of the channel.

Capillary leakage is undesirable for numerous reasons. For example, leaked aerosolizable material 200 may cause inconvenience and/or be unpleasant and thereby negatively affect user experience. Also, leaked aerosolizable material 200 is wasted. Moreover, leaked aerosolizable material 200 may affect performance of the system 10 and/or cause a user to perceive that the system 10 is faulty.

In the article 100 of the present invention, at least one of the opposing surfaces 106-109 comprises at least one surface feature 111 for inhibiting or preventing capillary flow of an aerosolizable material 200 from the reservoir 104 through the capillary channel 110. The surface feature 111 interrupts capillary flow of aerosolizable material 200 through the capillary channel 110 and thereby inhibits or prevents capillary leakage of 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 a groove 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 force cannot be sustained, and thus reduces or prevents aerosolizable material being drawn through the channel. Moreover, the capillary force of the opposing surfaces 106-109 is believed to hold the aerosolizable material 200 within the capillary channel 110 upstream of the at least one groove 111 (as illustrated in FIG. 3).

By virtue of the sealing effect of the at least one surface feature 111, a dedicated (e.g. separate and/or non-integral) sealing element for inhibiting or preventing capillary flow of aerosolizable material 200 from the reservoir 104 through the capillary channel 110, such as an O-ring may not be required. Thus, the article 100 of the present invention can be manufactured without the inclusion of such a dedicated sealing element. Indeed, the at least one surface feature 111 may be the only means for inhibiting or preventing capillary flow of an aerosolizable material from the reservoir 104 through the capillary channel 110. Accordingly, the article 100 of the present invention can be more cost-effective to manufacture relative to prior art articles, since the material cost of providing the dedicated sealing element can be avoided. Moreover, the article 100 of the present invention can be more straightforward to manufacture relative to prior art articles, since the step of assembling a dedicated sealing element in the article can be avoided. Furthermore, the article 100 of the present invention can be more reliable than prior art articles, since the risk of degradation, malfunction and/or defectiveness of the dedicated sealing element can be avoided. These issues are especially pertinent to articles having soft seals such as O-rings, which can be manufactured with defects and may degrade over time, e.g. due to exposure to certain chemicals and/or certain environmental conditions. Additionally, even though a dedicated sealing element, such as an O-ring, is not included, it is possible to form the respective parts of the housing from a similar material whilst still inhibiting or preventing leakage of aerosolizable material. This simplifies manufacture.

In the embodiment of FIG. 2, the housing 101 is of a generally cylindrical form and has a top end (opposite from the second section 103) and a bottom end (at the second section 103). The housing 101 has a longitudinal axis extending between its top and bottom ends. However, it will be appreciated by the skilled person that the housing 101 and its first and second sections 102, 103 may be provided in a variety of different forms. For example, the housing 101 may be of a generally polygonal form, such as a generally rectangular prismatic form. For example, the housing 101 may be of a generally plate-like form. For example, the housing 101 may taper towards one or both ends.

In the embodiment of FIG. 2, the first section 102 is of a generally cylindrical form. The first section 102 has a receiving portion 112 in the form of an end defining an opening to a space. The precise form 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 of a generally plate-like form. The second section 103 has an insertion portion 113 that is inserted into receiving portion 112. The second section 103 has an abutment portion 114 extending radially from the insertion 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 explained above, the precise form 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 more than one (e.g. two, three, four, five or six) pair of opposing surfaces 106, 108 and 107, 109. In the embodiment of FIG. 2, a first surface 106 of the first section 102 and a first surface 108 of the second section 103 are opposing, and a second surface 107 of the first section 102 and a second surface 109 of the second section 103 are opposing, thereby to provide two pairs of opposing surfaces 106, 108 and 107, 109.

One, more of each pair of opposing surfaces 106, 108 and 107, 109 may independently extend substantially axially, or extend substantially radially, or extend substantially obliquely, with respect to an axis of the housing 101. The axis of the housing 101 may be the axis extending between the ends (i.e. the top end and the bottom end) of the housing 101. 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 together (as described below).

In the embodiment of FIG. 2, one pair of opposing surfaces 106, 108 extends substantially axially with respect to the longitudinal axis of the housing 101, and another pair of opposing surfaces 107, 109 extends substantially radially with respect 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 explained above, a capillary channel 110 is provided between the opposing surfaces 106, 108 and 107, 109.

The skilled person will appreciate that the capillary channel 110 is shown schematically in the Figs. For example, the manner in which the first section 102 and the second section 103 are connected together is such that portions of the opposing surfaces 106-109 will be in contact with each other, but other portions of the opposing surfaces 106-109 will be spaced apart to form the capillary channel 110. The precise form of the capillary channel 110 is likely to vary from one article to another, since manufactured articles are non-identical at least in part due to manufacturing tolerances. The skilled person will appreciate that the opposing surfaces 106-109 may be provided in various different forms, which can 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 opposing surfaces 106-109 comprises more than one surface feature 111 for inhibiting or preventing capillary flow of an 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, more than one of the opposing surfaces 106-109 comprises at least one surface feature 111 for inhibiting or preventing capillary flow of an aerosolizable material from the reservoir through the capillary channel (as shown in FIG. 12).

In the illustrated embodiments, each surface feature 111 is a groove (although it will be understood that other surface features are envisaged). The groove(s) 111 may take a variety of different forms and configurations. In the embodiment of FIG. 2, each groove 111 is substantially straight when viewed side-on (as shown in FIG. 5). In other embodiments, the at least one groove 111 may be substantially curved when viewed side-on (as shown in FIG. 6). In other embodiments, the at least one groove 111 may be of an undulating form when viewed side-on (as shown in FIG. 7). In other embodiments, the at least one groove 111 may form a tortuous path (as shown in FIG. 8) when viewed side-on. For example, the at least one groove 111 may form a zig-zag when viewed side-on. An advantage of a substantially curved (e.g. undulating or tortuous) or zig-zag groove is that it can cover a large surface area. By covering a large surface area, the risk of capillary leakage may be further reduced.

In the embodiment of FIG. 2, each groove 111 has a substantially polygonal cross section where the cross section is taken perpendicular to the groove 111 (see e.g. FIG. 9). In other embodiments, at least one groove 111 may have a substantially curved or U-shaped cross section where the cross section is 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 comprises two grooves 111. In some embodiments, at least one opposing surface 106 of the first section 102 comprises at least one groove 111 (as shown in FIG. 11).

Where there is more than one pair of opposing surfaces 106, 108 and 107, 109, at least one of the opposing surfaces of each pair may comprise 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 comprises at least one surface feature 111, and the (radial) opposing surface 109 of the second section 103 comprises at least one surface feature 111. In FIG. 14, the (axial) opposing surface 106 of the first section 102 comprises at least one surface feature 111, and the (radial) opposing surface 107 of the first section 102 comprises at least one surface feature 111.

In the embodiment of FIG. 2, the surface features 111 are spaced apart from each other and each surface feature 111 is of a substantially annular form. 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 intercepted by the at least one surface feature 111. This configuration is effective in preventing capillary leakage of aerosolizable material from the reservoir. More specifically, each surface feature 111 extends continuously around the opposing (axial) surface 108 of the second section such that aerosolizable material 200 cannot flow from the reservoir 104 through the capillary channel without being intercepted by at least one surface feature 111.

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

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

The skilled person will appreciate that the groove(s) 111 may be provided in a variety of forms and dimensions. For example, the groove(s) 111 may be of a generally annular form, or may not be of an annular form.

In embodiments, 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 e.g. FIG. 2). For example, one of the first section 102 and the second section 103 may at least partially surround the other of the first section 102 and the second section 103 to form the connection between the first section 102 and the second section 103. For example, one of the first section 102 and the second section 103 may at least partially surround the other of the first section 102 and the second section 103 to provide at least one pair of the opposing surfaces 106, 108. Thus, one of the first section 102 and the second section 103 may 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 envisaged.

The first section 102 and the second section 103 may be connected together by an engineering fit. For example, the first section 102 and the second section 103 may be connected together by an interference fit, a press fit, a friction fit, and/or a transition fit. These fits provide for a reliable connection and can simplify the manufacture of the article 100.

In embodiments, one of the first portion 102 and the second portion 103 at least partially surrounds the other of the first portion 102 and the second portion 103 to form the connection between the first section 102 and the second section 103, wherein the connection is one or more of an interference fit, a press fit, a friction fit, and/or a transition fit. By virtue of this arrangement, a simple and reliable connection can be formed between the first section 102 and the second section 103. Accordingly, separate fastening means (e.g. screws and pins) for connecting the first section 102 and the second section 103 together may not be required, such that fewer components having a failure potential may be required.

In the embodiment of FIG. 2, the receiving portion 112 surrounds the insertion portion 113 so as to provide an interference fit, a press fit, a friction fit, and/or a transition fit between the first section 102 and the second section 103. The skilled person will be familiar with how to provide such types of engineering fit, 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 between 4 and 80. In the context of the present invention, hardness is measured using the Shore A scale. Such a hardness has been found to result in a surface feature 111 that is particularly effective at sealing against capillary leakage.

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

The opposing surfaces 106-109 may be made of 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 of, or treated by, a hydrophobic material. A hydrophobic material can help inhibit or prevent movement of aerosolizable material by capillary action, and thus can help inhibit or prevent capillary leakage via the capillary channel.

Non-limiting examples of suitable materials for use as the 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 of any of the materials disclosed herein. The second section 102 may be formed of any of the materials disclosed herein.

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

To connect the first section 102 and the second section 103 together, the first section 102 and the second section 103 may be pushed together. This may result in at least part of one of the first section 102 and the second section 103 being inserted into the other of the first section 102 and the second section 103 (depending on the form of the first section 102 and the second section 103 respectively). In other words, this may result in one of the first section 102 and the second section 103 at least partially surrounding the other of the first section 102 and the second section 103.

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

Aerosolizable material 200 can be deposited in the reservoir 104 before connecting together the first section 102 and the second section 103. Alternatively, aerosolizable material 200 may be deposited in the reservoir 104 after the first section 102 and the second section 103 have been connected together, e.g. by inserting the aerosolizable material 200 through an aperture (not shown) in the housing 101 which is subsequently sealed (e.g. by heat). Typically, the aerosolizable material 200 is a liquid (although gels may also be used).

Whilst the surface features 111 are grooves in the illustrated embodiments, it is envisaged that other forms of surface feature may be used. For example, the surface feature may comprise a hydrophobic material (e.g. a hydrophobic coating).

The Figs. presented 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 utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

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