EP4623729A1

EP4623729A1 - Article for use with an aerosol provision device

Info

Publication number: EP4623729A1
Application number: EP24167714.5A
Authority: EP
Inventors: Marcus Hartley
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2024-03-28
Filing date: 2024-03-28
Publication date: 2025-10-01
Also published as: WO2025202443A1

Abstract

There is provided an article for use with an aerosol provision device. The article has a heating arrangement comprising an open pore cellular member defining at least part of a flow path through the heating arrangement.

Description

Technical Field

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

Background

Smoking articles such as cigarettes, cigars and the like burn tobacco during use to create tobacco smoke. Attempts have been made to provide alternatives to these articles that burn tobacco by creating products that release compounds without burning. Examples of such products are heating devices which release compounds by heating, but not burning, the material. The material may be for example tobacco or other non-tobacco products, which may or may not contain nicotine.

Summary

In accordance with some embodiments described herein, there is provided an article for use with an aerosol provision device, the article comprising: a heating arrangement comprising an open pore cellular member defining at least part of a flow path through the heating arrangement.
The open pore cellular member may act as a matrix.
The aerosol-generating material may be disposed within the pores of the open pore cellular member.
The open pore cellular member may form a heating member.
The heating arrangement may comprise a heating member adjacent to the open pore cellular member.
The heater arrangement may comprise a heating member embedded in the open pore cellular member.
The heating member may comprise a layer of heating material.
The heating member may be a foil.
The open pore cellular member may be directly heated to act as the heating member.
The open pore cellular member may be indirectly heated by the heating member.
The open pore cellular member may be heated by the heating member to act as a heating element.
The open pore cellular member may be a susceptor.
The heating member may comprise a thermally conductive material.
The open pore cellular member may be heated indirectly by conduction by an adjacent heating member. The adjacent heating element may be a susceptor. The heating member may form part of the heating arrangement of the article. The heating member may form part of the aerosol provision device.
The porosity of the open pore cellular member may be constant along the length of the open pore cellular member. The porosity of the open pore cellular member may vary along the length open pore cellular member. The article may comprise an aerosol generating material. The aerosol generating material may be on the open pore cellular member. The aerosol generating material may be applied on the open pore cellular member. The aerosol generating material may be bonded on the open pore cellular member. The aerosol generating material may be a coating on the open pore cellular member. The aerosol generating material may be a coating on a surface of the open pore cellular member.
The aerosol generating material may be a non-liquid material.
The aerosol generating material may be a solid material.
The aerosol generating material may be a semi-solid material. The semi-solid material may be a gel.
The open pore cellular member may comprise cellular walls. The cellular walls may define an inner surface of the open pore cellular member. The aerosol generating material may be a coating on the inner surface of the open pore cellular member.
The aerosol generating material may be on at least a portion of the cellular walls.
The open pore cellular member may comprise a porous foam material.
The open pore cellular member may comprise a porous metal material.
The open pore cellular member may comprise a metal foam. The open pore cellular member may comprise a ceramic foam.
The open pore cellular member may be a rod shape. The open pore cellular member may be a planar shape.
The open pore cellular member may be an open pore cellular layer.
The heating member may be arranged to heat the aerosol generating material.
The heating member may be a resistive heating member configured to be heatable by passing a current through the heating member.
The heating member may comprise a heating material that is heatable by penetration with a varying magnetic field. The article may comprise a support.
The heating member adjacent to the open pore cellular member may form the support.
The open pore cellular member may contact the support.
The support may be a metallic support. The support may be at least one of a metal or a ceramic.
The article may comprise a plurality of discontinuous open pore cellular member portions on the support. The device may be configured to heat the aerosol generating material on each of the plurality of discontinuous open pore cellular member portions independently.
The article may be a planar article.
The article may comprise a plug of material. The plug of material may be at the distal end of the article. The plug may at least partially block airflow into the distal end of the article.
In accordance with some embodiments described herein, there is provided an aerosol provision device comprising: a receptacle configured to at least partially receive the article of any preceding claim, the receptacle being configured to be a heating chamber for heating the article, wherein the device is configured to direct air through the article.
The aerosol provision device may comprise a heating member.
In accordance with some embodiments described herein, there is provided an aerosol provision system comprising an aerosol provision device and the article as described above.
The device may be configured to direct air through the article such that the air passes through the open pore cellular member.
The device may comprise a power supply to generate electrical current for heating the heating member by resistive heating.
The device may comprise an induction coil to generate a magnetic field for heating the heating member by induction.
In accordance with some embodiments described herein, there is provided a method of manufacturing an article for an aerosol provision device comprising: providing an open pore cellular member for use with an aerosol provision device; and applying an aerosol generating material within the open pore cellular member.
The method may comprise heating the open pore cellular member to relatively dry the aerosol generating material within the open pore cellular member.
Applying of the aerosol generating material may include spraying the aerosol generating material onto the open pore cellular member.
Applying of the aerosol generating material may include submerging the open pore cellular member in the aerosol generating material.
The open pore cellular member may be a metal foam. The open pore cellular member may be a ceramic foam.
The open pore cellular member may comprise at least one of an Aluminium, steel or ceramic foam.
The aerosol generating material may be a liquid or gel.
The aerosol generating material may be a tobacco product.
The method may further comprise disposing the open pore cellular member on a support.
The method may comprise wrapping the infused open pore cellular member in a foil. The metal support may be an induction heating component. The open pore cellular member may be an induction heating component.

Brief Description of the Drawings

Embodiments will now be described, by way of example only, and with reference to the accompanying drawings in which:

Figure 1 shows a schematic cross sectional view of an aerosol provision system;
Figure 2 shows a schematic perspective view of an aerosol provision device;
Figure 3 shows a schematic perspective view of open pore cellular material;
Figure 4 shows a schematic perspective view of an open pore cellular member;
Figure 5 shows a schematic perspective view of an aerosol forming article;
Figure 6 shows a schematic perspective view of an embodiment of an aerosol forming article;
Figure 7 shows a flow chart of a method of manufacture of an aerosol forming article;
Figure 8 shows a method step of the method of manufacture of Figure 7;
Figure 9 shows a method step of the method of manufacture of Figure 7;
Figure 10 shows a method step of the method of manufacture of Figure 7;
Figure 11 shows a method step of the method of manufacture of Figure 7;
Figure 12 shows a method step of the method of manufacture of Figure 7; and
Figure 13 shows a method step of an embodiment of a method of manufacture of an aerosol forming article.

Detailed Description

As used herein, the term "aerosol-generating material" is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. Aerosol-generating material may include any plant-based material, such as tobacco-containing material and may, for example, include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. Aerosol-generating material also may include other, non-tobacco, products, which, depending on the product, may or may not contain nicotine. Aerosol-generating material may for example be in the form of a solid, a liquid, a gel, a wax or the like. Aerosol-generating material may for example also be a combination or a blend of materials. Aerosol-generating material may also be known as "smokable material".
The aerosol-generating material may comprise a binder and an aerosol former. Optionally, an active and/or filler may also be present. The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of 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. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In some embodiments, the aerosol-generating material is substantially tobacco free.
The aerosol-generating material may comprise or be an "amorphous solid". The amorphous solid may be a "monolithic solid". In some embodiments, 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 embodiments, the aerosol-generating material may, for example, comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.
The aerosol-generating material may comprise an aerosol-generating film. The aerosol-generating film may comprise or be a sheet, which may optionally be shredded to form a shredded sheet. The aerosol-generating sheet or shredded sheet may be substantially tobacco free.
According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.
In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.
In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.
In some embodiments, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.
In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.
An aerosol generating device can receive an article comprising aerosol generating material for heating. An "article" in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into the aerosol generating device before it is heated to produce an aerosol, which the user subsequently inhales. The article may be, for example, of a predetermined or specific size that is configured to be placed within a heating chamber of the device which is sized to receive the article.
With reference to Figure 1, an aerosol provision system 10 comprises an aerosol provision device 100 for generating aerosol from an aerosol generating material. The aerosol provision system 10 further comprises an article 110 comprising the aerosol generating material. The article 110 may be replaceable. In broad outline, the aerosol forming device 100 may be used to heat the article 110 to generate an aerosol or other inhalable medium, which is inhaled by a user of the device 100. In use, the article is inserted into the device for heating.
The aerosol provision device 100 comprises a body 102. A housing arrangement surrounds and houses various components of the body 102. An aperture 104 is formed at one end of the body 102, through which the article 110 may be inserted for heating by an aerosol generator located within the device.
The device 100 may also include a user-operable control element 150, such as a button or switch, which operates the device 100 when pressed. For example, a user may turn on the device 100 by operating the switch 150.
The aerosol generator defines a longitudinal axis 111, which aligns with an axis of the article 110.
In use, the article 110 may be fully or partially inserted into the aerosol generator where it may be heated by one or more components of the aerosol generator.
The device 100 includes an apparatus for heating aerosol-generating material. The apparatus includes an aerosol generating assembly, a controller (control circuit) 160, and a power source 170. The apparatus forms part of the body 102. The aerosol generating assembly is configured to enable heating of the aerosol-generating material of the article 110 inserted through the article aperture 104, such that an aerosol is generated from the aerosol generating material. The power source supplies electrical power to the aerosol generating assembly, and the aerosol generating assembly converts the supplied electrical energy into heat energy for heating the aerosol-generating material. The power source may be, for example, a battery, such as a rechargeable battery or a non-rechargeable battery. Examples of suitable batteries include, for example, a lithium battery (such as a lithium-ion battery), a nickel battery (such as a nickel-cadmium battery), and an alkaline battery.
The power source 170 may be electrically coupled to the aerosol generating assembly to supply electrical power when required and under control of the controller 160 to heat the aerosol generating material. The control circuit may be configured to activate and deactivate the aerosol generating assembly based on a user input. The user input may be via a button press or opening a door of the device (for example, a door covering a article receiving receptacle). The control circuit may be configured to activate and deactivate automatically, for example on insertion of an article.
The aerosol generating assembly may comprise various components to heat the aerosol generating material via an inductive heating process. Induction heating is a process of heating an electrically conducting heating element (such as a susceptor) by electromagnetic induction. An induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a varying electric current, such as an alternating electric current, through the inductive element. The varying electric current in the inductive element produces a varying magnetic field. The varying magnetic field penetrates a susceptor (heating element) suitably positioned with respect to the inductive element, and generates eddy currents inside the susceptor. The susceptor has electrical resistance to the eddy currents, and hence the flow of the eddy currents against this resistance causes the susceptor to be heated by Joule heating. In cases where the susceptor comprises ferromagnetic material such as iron, nickel or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e. by the varying orientation of magnetic dipoles in the magnetic material as a result of their alignment with the varying magnetic field. In inductive heating, as compared to heating by conduction for example, heat is generated inside the susceptor, allowing for rapid heating. Further, there need not be any physical contact between the inductive element and the susceptor, allowing for enhanced freedom in construction and application.
Figure 2 shows an example aerosol provision device 200 for generating aerosol from aerosol generating material. The aerosol generating material is provided in an article, which is described in detail below. The arrangement of the system of Figure 1, in which an article is received by the device through an opening at the proximal end, differs from the arrangement of Figure 2 in the article is received on a side of the device. However, features of each arrangement are applicable to each other.
The aerosol provision device 200 in Figure 2 is configured to receive a flat article (see Figure 4). The device 200 and article define an aerosol provision system. In embodiments, the device 100 of Figure 1 is configured to receive a flat article, and the device 200 of Figure 2 is configured to receive a rod-shaped article. The flat article is receivable in the device and is replaceable. The device 200 may be used to heat the replaceable article, also known as a consumable.
The aerosol provision device 200 extends from a proximal, mouth, end of the device to a distal end to form a device axis A. The device 200 has a body 202 that is openable by the user. The opening and closing of the device 200 is facilitated by a cover 204. The device 200 can be closed by covering an opening 206 and opened by uncovering the opening 206. The device 200 being in a closed state is said to be the first configuration of the device 200. The device 200 being in an open state is said to be the second configuration of the device 200.
Opening the device 200 by uncovering the opening 206 is performed by the user to replace the replaceable article, but may, in embodiments, be used to perform other maintenance tasks such as cleaning the device. In embodiments, the cover is omitted. The cover 204 of the device 200 can be opened to reveal a receptacle 208 for receiving the article. The receptacle 208 may also be known as a chamber. The opening 206 is an opening to the receptacle 208, granting the user access to the receptacle 208. The receptacle 208 comprises a proximal, mouth, end 212 and a distal end 214.
The device 200 is configured to receive the article in the receptacle 208. The receptacle 208 in the shown device 200 is provided at a distal end 216 of the device 200. The distal end 216 of the device 200 is configured to be held by the user. The proximal, or mouth, end 218, of the device 200 is configured to act as a mouthpiece. The receptacle 208 is insulated such that heat is not transmitted through the device 200. The heat is retained within the receptacle 208 to improve heating efficiency. At least a portion of the article is received within the device 200.
The receptacle 208 of the device 200 is a heating chamber. The heating chamber 208 defines a heating zone. The heating chamber 208 comprises an extent having a length L, a width W perpendicular to the length L, and a depth D perpendicular to each of the length L and the width W, wherein the length L is greater than or equal to the width W, and wherein the width W is be greater than the depth D. The article received in the heating chamber 208 comprises an extent having a length, a width perpendicular to the length, and a depth perpendicular to each of the length and the width, wherein the length is greater than or equal to the width, and wherein the width is be greater than the depth. The system comprises a heating assembly 222. The heating assembly 222 is configured to provide heat in the heating zone 208.
The shown cover 204 in Figure 2 is a hinged cover. The cover 204 may open and close like a door. The device 200 may open and close in accordance with a book or folder like design. The cover 204 extends in a direction parallel to the device axis A. A hinge 224 of the cover 204 extends in in a direction parallel to the device axis A such that the cover pivots in a perpendicular, or lateral, direction to the device axis A, similar to opening a book or a door. The cover 204 of the device 200 may be releasably secured into the closed position by any suitable means. Examples include a releasable catch, clasp or feature, a magnet. In embodiments, the hinge 224 of the cover 204 may be configured to extend in a perpendicular, or lateral, direction to the device axis A. In this embodiment, the device 200 may be considered to more closely emulate a notebook, wherein the cover 204 pivots such that it opens in a direction parallel to of the axis A. In embodiments, the cover 204 is a slidable cover. The slidable cover may slide in a direction parallel to an axis A along which the device 200 extends. The slidable cover may slide in a direction perpendicular to the axis A.
The device 200 of Figure 2 comprises a heating assembly 222. The heating assembly 222 comprises a plurality of coils 228. Each of the plurality of coils 228 can be selectively activated to heat at least a portion of the article in use. Each coil of the plurality of coils 228 can be independently activated. The plurality of coils 228 are arranged linearly. Each coil of the plurality of coils 228 is spaced from adjacent coils of the plurality of coils 228. The coils are arranged in the chamber along the longitudinal axis A. Each coil of the plurality of coils 228 is an induction coil. Each induction coil generates a magnetic field. The magnetic field is configured to heat the article. The magnetic field is configured to penetrate a susceptor of the article to induce heating in the article. The heating assembly 222 may be electrically connected to a power source 260. A controller 270 enables power to be provided to each of the plurality of heating members 228. In embodiments, a single coil is provided. In embodiments the coils are flat, planar coils.
In embodiments, each coil of the plurality of coils 228 may be a resistive heating coil. In such an embodiment, the resistive heating coils form a heating assembly that is external to the article. A resistive heating assembly of the device is an external heating arrangement. The article comprises a heating arrangement as described below. The heating arrangement comprises a heating member as described below. The heating arrangement transfers heat to the aerosol generating material. The heating arrangement may be directly or indirectly heated. For example, the article heating member may be heated by a resistively or inductively heated heating element of the device. In embodiments, the article heating member is itself an article heating element. The article heating element in embodiments is a susceptor of an inductively heated system. In embodiments, the article heating element is a resistive heating element. In such an arrangement an electrical connector arrangement is provided between the device and the article.
Figure 3 shows a section of an open pore cellular material 300. The open pore cellular material 300 forms part of the article of the aerosol provision system. An open pore cellular material 300 is considered to be a unitary piece of material. A "pore" is considered to be a small opening or void in what would be an otherwise solid material. A porous material is a material that comprises a number of small openings or voids. A material that is "open pore" is considered to be a material comprising pores that connect to outer surfaces of the material, including via other intermediate pores. Open pores are voids in a material that are exposed to the external environment of the material.
A material that is "cellular" is considered to be a material with a structure that comprises cells and wherein a plurality of cells are connected. Pores and cells may be used interchangeably. A cellular material in the context of this description is a material comprising voids resembling cells, wherein fluid exchange can occur between individual voids. An open pore cellular material comprises fluidly connected cells. The open pore cellular member comprises cellular walls. The cellular walls define the cells. An open pore cellular material is therefore a material wherein at least a portion of the material comprises at least some pores that are fluidly connected to each other. At least some of the pores are on at least a portion of an outer surface of the material. An open pore cellular material is fluid permeable to the extent that fluid may pass in the pores. A foam in embodiments is an open pore cellular material.
An open pore cellular member 400 as shown in Figure 4 is formed from the open pore cellular material 300. The open pore cellular member 400 is formed by machining, cutting, deforming, casting or otherwise shaping the open pore cellular material 300.
The open pore cellular material 300 is formed as a metal material. The metal open pore cellular material 300 may be steel. In embodiments, the metal open pore cellular material 300 is another suitable material, such as aluminium. In embodiments, the open pore cellular material 300 is made of other suitable materials, such as a ceramic material. The open pore cellular member 300 may comprise a ceramic foam. The open pore cellular member is advantageous because it is able to retain a relatively large quantity of aerosol generating material. The open pore cellular member is able to retain a relatively large quantity of aerosol former. Further, the quantity of aerosol generating material retained in the open pore cellular member could be altered by altering the porosity of the open pore cellular member.
The open pore cellular material 300 in embodiments is thermally conductive. The open pore cellular material 300 can therefore act, in embodiments, as a heating element of the heating arrangement. The open pore cellular material 300 in embodiments is electrically conductive. The open pore cellular material 300 can therefore, in embodiments, act as a resistive heating element of the heating arrangement.
In embodiments, the article comprises a combination of materials. In embodiments, a first open pore cellular member may comprise a metallic sponge core and a second open pore cellular member may comprise a ceramic sponge coating. The metallic sponge core may be suitable for heating. The ceramic sponge coating may be suitable for handling by the user. The ceramic sponge coating may act as an insulating layer. The insulating layer may insulate the open pore cellular member so that it can be handled by the user.
In embodiments, the metallic open pore cellular member acts as an induction heating member, and therefore forms a heating element of the heating arrangement. In embodiments, the metallic open pore cellular member acts as a resistive heating member, and therefore forms a heating element of the heating arrangement. As a resistive heating element, the heating arrangement reduces the number of electrical connections required as the member itself is fully conductive. The density of the porous structure may be tuned. By tuning the density, the rate of liquid flow through the member can be controlled control. Similarly the resistance of the heating member may be tuned to determine the required heating attributes.
The open pore cellular member may be mouldable. The open pore cellular member maximises surface area of the member. A large surface area provides efficient aerosol generation. In embodiments, the open pore cellular member may be re-applied with aerosol generating material after use.
Figure 4 shows the open pore cellular member 400. The open pore cellular member is flat. The open pore cellular member is a planar shape. The open pore cellular member defines the article 110. The article 110 comprises that open pore cellular member 400 and an enclosure (not shown in Figure 4). The enclosure may be a wrap. The enclosure may be a paper wrap. The enclosure defines the flow path through the open pore cellular member 400. The flow path may extend the length of the open pore cellular member 400. The enclosure may define an inlet and an outlet at opposing ends of the open pore cellular member 400. In embodiments, the open pore cellular member 400 forms at least a portion of an article 500 as shown in Figure 5.
The open pore cellular member 400 acts as a matrix. The open pore cellular member 400 is insertable into the device 100, 200 as part of the article. The open pore cellular member 400 defines a layer. The open pore cellular member 400 defines an open pore cellular member layer. The open pore cellular member 400 is heatable. The open pore cellular member 400 is configured to be a heater member. In embodiments the heating arrangement is an inductive heating arrangement. The metal sponge is configured to be a susceptor member. The metal sponge is heatable by penetration by a magnetic field. The open pore cellular member as the heating member is heated directly. The open pore cellular member 400 in such embodiments defines the heating member of the heating arrangement.
In embodiments, the open pore cellular member 400 is heatable by resistive heating. The open pore cellular member 400 is connectable to the power source of the device. An electrical connector arrangement, including for example a first type (for example, positive connector) and a second type (for example, negative connector) of electrical contacts may be provided. The open pore cellular member 400 is configured to conduct electrical power. When electrical power is passed through the open pore cellular member 400, the open pore cellular member 400 is heated. The open pore cellular member 400 in such embodiments defines the heating member of the heating arrangement.
In other embodiments, the open pore cellular member 400 is conductively heated. The open pore cellular member may be heated indirectly by conduction by an adjacent heating element of the device. The open pore cellular member may be heated indirectly by conduction by an adjacent heating element of the article The open pore cellular member 400 in such embodiments defines the heating member of the heating arrangement. The external heater may be a resistive heater element. The heating element may be a resistive heating element configured to be heatable by passing a current through the heating element. The open pore cellular member 400 may conduct thermal energy produced by the heater assembly of the device. In embodiments, a heater member may be embedded in the open pore cellular member. The embedded heater member may be a core. The embedded heater member may be a resistive heater. The embedded heater member may be an induction heater. The embedded heater member may extend along a longitudinal axis of the open pore cellular member.
The porosity of the open pore cellular member is constant along the length of the open pore cellular member. In embodiments, the porosity of the open pore cellular member may vary along the length open pore cellular member. In this embodiment a first portion of the open pore cellular member is more porous than a second portion of the open pore cellular member. The first portion may be at the proximal end, and the second portion may be at the distal end, or vice versa. Other configurations of an open pore cellular member with varying porosity along the length are anticipated. A varying porosity may be advantageous because the porosity of the open pore cellular member is used to control the aerosolisation of the aerosol-generating material. For example, an open pore cellular member with a higher porosity has a higher surface area. This will affect the amount of aerosol produced over a period of time. The aerosolization of the aerosol generating material may be tuned by adjusting the porosity of the open pore cellular member.
Figure 5 shows another article 500. The article 500 is a flat article. The article 500 is a strip. The article 500 extends along a longitudinal axis 502. The article 500 has a length P and a width Q. The article 500 has a proximal end 504 and distal end 506. The article 500 at least partially defines an airflow path 508 along the length of the article 500.
The article 500 comprises a plurality of layers 512. The article 500 comprises a open porous layer 514, a heater layer 516, and a support 518. The support 518 is a support layer. The porous layer 514 is an open pore cellular member. The porous layer 514 is the open pore cellular member 400 as described in relation to Figure 4. The airflow path 508 of the article passes through the open pores of the open pore cellular member 400. The airflow path 508 extends from the distal end 506 to the proximal end 504 of the article 500. In embodiments, the article has a different configuration. The article may comprise any number of layers, including just one layer. For example, in embodiments in which the open pore cellular member is the heating member, then the separate heater layer 516 may be omitted. The article may comprise layers disposed in any order. The article 500 may comprise only an open pore cellular member 400 as described in relation to Figure 4.
The article 500 comprises the aerosol generating material 520. The porous layer 514 comprises the aerosol generating material 520. The aerosol generating material 520 is contained within the open pore cellular member 400. The aerosol generating material 520 is within the pores of the open pore cellular member 400.
The aerosol generating material 520 is a non-liquid material. The aerosol generating material 520 is on the open pore cellular member. The aerosol generating material 520 is mounted on the open pore cellular member 400. The aerosol generating material 520 forms a layer. The aerosol generating material 520 forms a coating. The aerosol generating material layer is interspersed on the inner surface of the open pore cellular member 400.
The aerosol generating material 520 in embodiments is a solid material. The aerosol generating material 520 in embodiments is a semi-solid material. The semi-solid material may be a gel. The gel is adherable to the open pore cellular member 400. The aerosol generating material is on at least a portion of the cellular walls. In embodiments, the aerosol generating material 520 may be disposed on the open pore cellular member 400 by dipping the open pore cellular member 400 into a bath of aerosol generating material 520. In embodiments, the aerosol generating material may be disposed on the open pore cellular member 400 by spraying the open pore cellular member 400 with aerosol generating material 520. The liquid may be sprayed onto the open pore cellular member 400 and dried to bind to the open pore cellular member 400.
The heater layer 516 of the article 500 is a sheet material. The heater layer 516 is a foil. The heater layer 516 is an aluminium foil. The heater layer 516 is adjacent the porous layer 514. The heater layer 516 is configured to conductively heat the porous layer 514. The heater layer 516 generates thermal energy that is transmitted through at least a portion of the porous layer 514. The heat transmitted through at least a portion of the porous layer 514 heats the aerosol generating material 520 within the pores. In embodiments, the heater layer 516 is one of inductively or resitively heated.
In embodiments, the heater layer 516 is a susceptor. The susceptor layer 516 is heatable by penetration of a magnetic field. In embodiments, the heater layer 516 and the porous layer 514 may each be a susceptor layer heatable by penetration of a magnetic field. In embodiments, the heater layer 516 may have a different configuration. The heater layer 516 may be a different material, such as a different metal material or a ceramic material.
The support 518 is adjacent the heater layer 516. The support 518 supports the heater layer 516. The heater layer 516 is in contact with the support 518. The heater layer 516 is mounted on the support 518. The support 518 is an insulative layer. The support 518 is a card material. The support may be a wrap.
Figure 6 shows an article 600. The article 600 is a rod. The article 600 is a rod-like article. The rod-like article 600 is a cylindrical shape. The article 600 extends from a distal end (not shown) to a proximal, mouth, end 604. The article 600 comprises a porous layer 606, a heater layer 608 and a support 610. Each of the porous layer 606, heater layer 608 and the support 610 have substantially the same configuration as the porous layer 514, heater layer 516, and support 518 described in relation to Figure 5 although the shape of each layer is different in this embodiment. Other shapes and configurations are anticipated. The features of each layer 514, 516, 518 described in relation to Figure 5 is applicable to the article 600 according to the embodiment of Figure 6 other than the shape of the layers.
The porous layer 606 comprises the open pore cellular member. The porous layer 606 is rod-like. The porous layer 606 acts as a core. The core 606 is a porous core. An airflow path 612 of the article 600 extends through the core 606. The heater layer 608 is wrapped around the core 606. The heater layer 608 is a tubular layer. The support 610 is wrapped around the heater layer 608. The support 610 is a tubular layer. The support is an insulative layer. The support 610 is a paper layer. The distal end (not shown) and proximal end 604 of the core 606 are uncovered. The uncovered distal end 602 is an inlet of the article 600. The uncovered proximal end 604 is an outlet of the article 600. In embodiments, the configuration of the article 600 may vary. The article may comprise any number of layers. The order of the layers may vary. The article 600 may only comprise the porous core 606. The heater layer 608 and the support 610 may be omitted. In embodiments, the heater layer 608 may act as a core of the article 600 and the porous layer 604 may be wrapped around the heater layer 608. In embodiments, one or more layers surrounding the porous layer could be substantially impermeable to liquid. In embodiments, a liquid-impermeable layer may surround the porous layer. The support 610 may be a liquid-impermeable layer. The liquid-impermeable layer may be an additional layer to those described. The liquid-impermeable layer may be, for example, glycerol. The liquid-impermeable layer is advantageous in embodiments where the porous layer 606 retains a relatively high amount of glycerol.
In an embodiment not shown in the figures, the article comprises a plug of material. The plug of material is at the distal end of the article. The plug of material in embodiments provides a pressure drop across the plug of material to the open pore cellular member. The plug at least partially restricts airflow at the distal end of the article. In embodiments, the plug may be formed using the support. The support layer may extend beyond the distal end of the porous layer. The plug comprises a paper material. In embodiments, the plug is a separate element. The plug is formed separately to the porous, heater and support layers. The plug is adjacent the distal end of the open pore cellular member to partially block airflow through the open pore cellular member, reducing the pressure. In this embodiment, the plug may comprise the same material as the support, or a different material. The plug may comprise paper or cellulose acetate. Other configurations of the plug are anticipated. The provision of the plug may allow the configuration of the open pore cellular member to have a greater range of properties.
Figure 7 shows a method of manufacture 700 in accordance with various embodiments. The method 700 comprises steps to produce an article 600 as provided with reference to Figure 6. The method of manufacturing 700 the article for an aerosol provision device comprises the method step of providing an open pore cellular member for use with an aerosol provision device 710. The method of manufacturing 700 the article for an aerosol provision device comprises the method step of applying an aerosol generating material within the open pore cellular member 720. In the method of manufacture 700, the open pore cellular member is provided pre-formed from open pore cellular material. In embodiments, the open pore cellular member may be formed in a method step of the method of manufacture, as described in relation to Figure 13.
In embodiments, the method of manufacture may comprise further optional steps, as shown in Figure 7. In embodiments, the method may further comprise drying the aerosol generating member 730. In embodiments, the method may further comprise wrap the open pore cellular member with a heater layer 740. In embodiments, the method may further comprise wrapping the open pore cellular member with a wrap 750. In embodiments, the method may further comprise forming an open pore cellular member. In embodiments, the method may further comprise forming an article. In embodiments, the method may further comprise forming an open pore cellular member and an article simultaneously.
Figure 8 shows the method step of providing open pore cellular member 710. The open pore cellular member 712 is substantially the same as the open pore cellular member 400, 514, 606 of any previous embodiment. The open pore cellular member 712 comprises a porous, absorbent sponge material. The open pore cellular member 712 is a metal sponge. The open pore cellular member 712 is provided in a rod-like shape. The rod-like shape is a cylindrical shape. In embodiments, the open pore cellular member 712 may be provided in a different configuration. The rod-like shape may be any prismatic shape. The prismatic shape may be a triangular, square, pentagonal, hexagonal etc. prism.
Figure 9 shows the method step of applying aerosol generating material to the open pore cellular member 720. The aerosol generating material 722 is applied within the open pore cellular member 712. The aerosol generating material 722 is sprayed on the open pore cellular member 712. The aerosol generating material 722 is atomised during the application. The aerosol generating material 722 is sprayed onto the open pore cellular member 712 in a plurality of separate columns 724. The method includes providing a plurality of sprayer devices 726. The plurality of sprayer devices 726 are fluidly connected to a container 728. The container 728 contains the aerosol generating material 722. The plurality of sprayer devices 726 are separated by a gap G. The plurality of sprayer devices 726 distribute the aerosol generating material 722.
Figure 10 shows the method step of drying the aerosol generating material 730. Drying may comprise heating the open pore cellular member 712. To heat the open pore cellular member 712 an external heater 732 is provided. The external heater 732 provides heat to the open pore cellular member 712 with aerosol generating material 722 recently applied to it. The aerosol generating material 722 dries in the pores of the open pore cellular member 712. The aerosol generating material 722 is trapped within the pores. The aerosol generating material 722 binds to the open pore cellular member 712. The binding between the open pore cellular member 712 and the aerosol generating material 722 may be referred to throughout as attaching, fixing, setting, adhering. In embodiments, the external heater 732 may not be needed. The aerosol generating material 722 may dry without the application of heat.
Figure 11 shows the method step of wrapping the open pore cellular member in a heater layer 740. The heater layer 742 wrapped around the open pore cellular member 712 is substantially the same heater layer 516, 608 as previously described in relation to Figure 5 and Figure 6. The heater layer 742 is wrapped around the open pore cellular member 712. The open pore cellular member 712 is a prism shape comprising a first base surface 734, located at the distal end 735 (see Figure 9), and a second base surface 736, located at the proximal end 737.
The open pore cellular member 712 comprises an outer surface 738 that extends between the first and second surface 734, 736. The heater layer 742 is wrapped around at least a portion of the outer surface 738. The heater layer 742 is secured to the open pore cellular member 712. The heater layer 742 is wrapped entirely around the outer surface 738. The outer surface 738 is covered by the heater layer 742. The first and second base surfaces 734, 736 are shown unwrapped.
The first and second base surfaces 734, 736 are uncovered. The heater layer 742 comprises a first edge 744 and a second edge 746. The first edge 744 and the second edge 746 are opposed edges. The heater layer 742 is wrapped around the outer surface 738 such that the opposed edges 744, 746 of the heater layer 712 overlap. The heater layer 712 is secured such that the first edge 744 is secured to the open pore cellular member 712. The second edge 744 overlaps the first edge 744. The overlapping portion of the second edge 746 is secured to the heater layer 712. In embodiments, the first edge 744 may not be secured to the open pore cellular member 712. The heater layer 742 is wrapped around the open pore cellular member 712 such that the second edge 746 overlaps the first edge 744, and the second edge 746 is attached to the first edge 744. In other embodiments, the heater layer 712 may only be wrapped around a portion of the outer surface 738. In these embodiments, the first and second edges 744, 746 of the heater layer 738 are attached to the open pore cellular member 712. In embodiments, the heater layer 738 may be omitted. In these embodiments, the open pore cellular member 712 is the heater arrangement.
Figure 12 shows the method step 750 of wrapping a paper layer 752 around the heating layer 742. The heating layer 742 comprises an outer surface 754. The paper layer 752 is wrapped around at least a portion of the outer surface 754. The paper layer 752 is secured to the heating layer 742. The paper layer 752 is wrapped entirely around the outer surface 754 of the heating layer 742. The outer surface 754 of the heating layer 742 is covered by the paper layer 752. The first and second base surfaces 734, 736 of the open pore cellular member 712 are unwrapped. The first and second base surfaces 734, 736 are uncovered. The paper layer 752 comprises a first edge 756 and a second edge 758. The first edge 756 and the second edge 758 are opposed edges.
The paper layer 752 is wrapped around the outer surface 754 of the heating layer 742 such that the opposed edges 756, 758 of the paper layer 752 overlap. The paper layer 752 is secured such that the first edge 756 of the paper layer 752 is secured to the heating layer 742. The second edge 758 of the paper layer 752 overlaps the first edge 756. The overlapping portion of the second edge 758 is secured to the paper layer 752. In embodiments, the first edge 756 may not be secured to the heating layer 742. The paper layer 752 is wrapped around the heating layer 742 such that the second edge 758 of the paper layer 752 overlaps the first edge 756, and the second edge 758 is attached to the first edge 756. In other embodiments, the paper layer 752 may only be wrapped around a portion of the outer surface 754 of the heating layer 742. In these embodiments, the first and second edges 756, 758 of the paper layer 752 are attached to the heating layer 742. In embodiments, the paper layer 752 may be omitted.
In embodiments, the heating layer 742 may be omitted. In these embodiments, the paper layer 752 is wrapped around the open pore cellular member 712 in substantially the same way as it has been described that the heating layer 742 is wrapped around the open pore cellular member 752. During the step of wrapping the open pore cellular member 712 with the heating layer 742, the heating layer 742 may be substituted with the paper layer 752.
Figure 13 shows a method step 760 according to an embodiment of the method of manufacture. In embodiments in which the open pore cellular material is not pre-formed into an open pore cellular member 712, a further step of forming the open pore cellular member 712 is needed. This method step may be performed before the method step 710, before method step 740, or after method step 750. In the shown embodiment, the method step 760 is performed after method step 750.
Open pore cellular material 761 is machined into an appropriate shape. Forming the open pore cellular member 712 comprises cutting the open pore cellular material 761. In the shown embodiment, the paper layer 752 and the heating layer 742 are wrapped around the open pore cellular material 761 and so are cut along with the open pore cellular material 761. In this embodiment, cutting the open pore cellular material 761 to an appropriate size is a method step of forming the article 600. The method step of forming the article 600 comprises making a first cut at a first location 762 of the open pore cellular material. The method step of forming the article 600 comprises making a second cut at a second location 764 of the open pore cellular material. The first and the second cut in the open pore cellular material form the open pore cellular member 712, as previously described.
In the shown embodiment, making the first and second cut forms the article 600. The article 600 has a length L. The formed article 600 comprises the open pore cellular member 712. The length L is the distance between the first location 762 and the second location 764. First cut forms the distal end 602 of the article 600. The second cut forms the proximal, mouth, end 604 of the article 600. The first base surface 734 of the open pore cellular member 712 is formed by the first cut. A second base surface 736 of the open pore cellular member 712 is formed by the second cut. The first base surface 734 is an inlet of the open pore cellular member 712. The second base surface 736 is an outlet of the open pore cellular member 712. An airflow path extends through the open pore cellular member 712. The airflow path extends from the first base surface 734 to the second base surface 736. The airflow path extends along the length of the article 600. The airflow path is bounded by the heater layer 742.
The first and second cut is performed by a first and second circular saw 768, 769 respectively. The first and second circular saw 768, 769 are each mechanically connected to an electrical motor 770 that causes the saws to rotate. The electrical motor 770 may be powered by suitable power source 772. In embodiments, the cutting may be performed by any suitable means. The cutting may be performed by laser cutting, liquid jet cutting, a waterjet cutting, plasma cutting etc. In embodiments, the article may be formed by another shaping means, such as stamping or milling.
In embodiments, the open pore cellular member 712 is wrapped in at least one of a heater layer 742 and a paper layer 752. In these embodiments, forming the article 600 comprises cutting the wrapped open pore cellular member 712. At least one of the heater layer 742 and the paper layer 752 wrapped around the open pore cellular member 712 are cut along with the open pore cellular member 712.
Figures 8 to 13 show that the method steps of the method of manufacture 700 are automated. The method steps of the method of manufacture are performed sequentially. The method steps are preformed on a production line. The open pore cellular member is provided on a conveyer 774 at the beginning of the method. The conveyer conveys the open pore cellular material from the beginning of the method to the final step of the method. The conveyer conveys the open pore cellular material between the method steps. The method steps are performed whilst the open pore cellular material is disposed on the conveyer.
The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

An article for use with an aerosol provision device, the article comprising:
a heating arrangement comprising an open pore cellular member defining at least part of a flow path through the heating arrangement.
The article of claim 1, wherein the open pore cellular member acts as a matrix.
The article of claim 1 or claim 2, wherein the aerosol generating material is disposed within the pores of the open pore cellular member.
The article of any of claims 1 to 3, wherein the open pore cellular member forms a heating member.
The article of any of claims 1 to 3, wherein the article comprises a heating member adjacent to the open pore cellular member.
The article of claim 5, wherein the heating member comprises a layer of heating material.
The article of any of claims 4 to 7, wherein the heating member is a susceptor.
The article of any of claims 4 to 7, wherein the heating member comprises a thermally conductive material.
The article of any of claims 1 to 8, wherein comprising an aerosol generating material, wherein the aerosol generating material is on the open pore cellular member.
The article of claim 9, wherein the aerosol generating material is a coating on a surface of the open pore cellular member.
The article of any of claims 1 to 10, wherein the aerosol generating material is a non-liquid material.
The article of any of claims 1 to 11, wherein the open pore cellular member comprises at least one of a porous foam material, a porous metal material, a porous ceramic material.
An aerosol provision system comprising an aerosol provision device and the article of any of claims 1 to 12.
The aerosol provision system of claim 13, wherein the device is configured to direct air through the article such that the air passes through the open pore cellular member.
A method of manufacturing an article for an aerosol provision device comprising:
providing an open pore cellular member for use with an aerosol provision device; and

applying an aerosol generating material within the open pore cellular member.