EP4683531A1

EP4683531A1 - Article

Info

Publication number: EP4683531A1
Application number: EP24714986.7A
Authority: EP
Inventors: Richard HAINES; James Sheridan
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-03-21
Filing date: 2024-03-20
Publication date: 2026-01-28
Also published as: CN121511026A; WO2024194633A1

Abstract

A substantially planar aerosol generating component (200) for use as part of a non-combustible aerosol provision system. The substantially planar aerosol generating component includes: an aerosol generating portion (201); and at least one electrical connection portion (202, 203). The at least one electrical connection portion includes an aperture (204) for receiving an electrical contact (1000). At least one section (202a, 203a) of the electrical connection portion extending to a perimeter of the aperture is predisposed to deformation.

Description

Article

Field

The present invention relates to an aerosol generating component for use as part of a noncombustible aerosol provision system, an article for use as part of a non-combustible aerosol provision system, and a non-combustible aerosol provision system.

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 generating component which is capable of converting an aerosolisable material into an aerosol. In some instances, the aerosol generated is a condensation aerosol whereby an aerosolisable material is first vaporised and then allowed to condense into an aerosol. In other instances, the aerosol generated is an aerosol which results from the atomisation of the aerosolisable material. Such atomisation may be induced mechanically, e.g. by subjecting the aerosolisable material to vibrations so as to form small particles of material that are entrained in airflow. Alternatively, such atomisation may be induced electrostatically, or in other ways, such as by using pressure.

Since such aerosol provision systems are intended to generate an aerosol which is to be inhaled by a user, consideration should be given to the characteristics of the aerosol produced. These characteristics can include the size of the particles of the aerosol, the total amount of the aerosol produced, etc.

Where the aerosol provision system is used to simulate a smoking experience, e.g. as an e- cigarette or similar product, control of these various characteristics is especially important since the user may expect a specific sensorial experience to result from the use of the system.

It would be desirable to provide aerosol delivery systems which have improved control of these characteristics.

Summary

According to an aspect of the present disclosure, there is provided a substantially planar aerosol generating component for use as part of a non-combustible aerosol provision system, the substantially planar aerosol generating component comprising: an aerosol generating portion; and at least one electrical connection portion comprising an aperture for receiving an electrical contact, wherein at least one section of the at least one electrical connection portion extending to a perimeter of the aperture is predisposed to deformation.

In one embodiment, the at least one section predisposed to deformation is deformable relative to an adjacent section of the aerosol generating component.

In one embodiment, the adjacent section is of the at least one electrical connection portion.

In one embodiment, the at least one section predisposed to deformation is of increased flexibility relative to the adjacent section.

In one embodiment, the at least one section predisposed to deformation is of reduced thickness relative to the adjacent section.

In one embodiment, the at least one section predisposed to deformation is separated by a line of weakness from the adjacent section.

In one embodiment, the at least one section predisposed to deformation is articulated to the adjacent section.

In one embodiment, the at least one section is predisposed to resilient deformation.

In one embodiment, the perimeter of the aperture defines a closed shape.

In one embodiment, the at least one section predisposed to deformation comprises a plurality of sections, wherein each of the sections is predisposed to deformation relative to an adjacent section of the aerosol generating component.

In one embodiment, the sections predisposed to deformation are spaced apart from each other.

In one embodiment, the substantially planar aerosol generating component is integrally formed.

In one embodiment, the aerosol generating section is porous.

In one embodiment, the at least one electrical connection portion comprises two electrical connection portions, each electrical connection portion being arranged at a respective end of the aerosol generating section.

In one embodiment, the aerosol generating section comprises at least one elongate aperture. In one embodiment, the elongate apertures are arranged in series along an axis (e.g. the longitudinal axis or the transverse axis) of the aerosol generating component. In one aspect, each of the elongate apertures extends non-parallel to an axis (e.g. the longitudinal axis or the transverse axis) of the aerosol generating component.

In one embodiment, the substantially planar aerosol generating component is formed from a single layer.

According to another 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 substantially planar aerosol generating component comprising: an aerosol generating portion; and at least one electrical connection portion comprising an aperture for receiving an electrical contact, wherein at least one section of the at least one electrical connection portion extending to a perimeter of the aperture is predisposed to deformation; and at least one electrical contact, wherein the electrical contact is received through the aperture, such that the electrical contact is connected to the at least one electrical connection portion.

In one embodiment, the at least one electrical connection portion comprises a plurality of (e.g. two) electrical connection portions. In one embodiment, the at least one electrical contact comprises a plurality of (e.g. two) electrical contacts. In one embodiment, an electrical contact is received through a respective aperture, such that each of the electrical connection portions is connected to a respective electrical contact.

The substantially planar aerosol generating component may be characterised in accordance with any other aspect of the present disclosure.

According to another aspect of the present disclosure, there is provided a non-combustible aerosol provision system comprising: an article comprising: a substantially planar aerosol generating component comprising: an aerosol generating portion; and at least one electrical connection portion comprising an aperture for receiving an electrical contact, wherein at least one section of the at least one electrical connection portion extending to a perimeter of the aperture is predisposed to deformation; and an electrical contact, wherein the at least one electrical contact is received through the aperture, such that the at least one electrical contact is connected to the at least one electrical connection portion; a power source; and a controller. In one embodiment, the at least one electrical connection portion comprises a plurality of (e.g. two) electrical connection portions. In one embodiment, the at least one electrical contact comprises a plurality of (e.g. two) electrical contacts. In one embodiment, an electrical contact is received through a respective aperture, such that each of the electrical connection portions is connected to a respective electrical contact.

Any feature of any aspect of the present disclosure may be combined with any other aspect of the present disclosure.

Brief Description of the Drawings

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

Fig. 1 is a schematic diagram of a non-combustible aerosol provision system according to the present disclosure;

Fig. 2 is a perspective view of an aerosol generating component for use as part of the noncombustible aerosol provision system of Fig. 1 ;

Fig. 3 is a side view of an electrical connection portion of the aerosol generating component of Fig. 2, wherein the electrical connection portion is connected to an electrical contact;

Fig. 4 is a perspective view of an aerosol generating component for use as part of the noncombustible aerosol provision system of Fig. 1, according to the present disclosure;

Fig. 5 is an enlarged perspective view of an electrical connection portion of the aerosol generating component of Fig. 4;

Fig. 6 is a side view of an electrical connection portion of the aerosol generating component of Fig. 4, prior to connection to an electrical contact;

Fig. 7 is a side view of an electrical connection portion of the aerosol generating component of Fig. 4, wherein the electrical connection portion is connected to an electrical contact;

Fig. 8A is a perspective view of an electrical connection portion of the aerosol generating component of Fig. 4 and an electrical contact, prior to connection between the electrical connection portion and the electrical contact; Fig. 8B is a perspective view of an electrical connection portion of the aerosol generating component of Fig. 4 and an electrical contact, wherein the electrical connection portion is being connected to the electrical contact; and

Fig. 8C is a perspective view of the electrical connection portion of the aerosol generating component of Fig. 4, and an electrical contact, wherein the electrical connection portion is connected to the electrical contact.

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 articles and systems discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

As described above, the present disclosure relates, but is not limited, to non-combustible aerosol provision systems and articles that generate an aerosol from an aerosol-generating material (also referred to herein as “aerosolisable material”) without combusting the aerosolgenerating 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 aerosolgenerating material is not a requirement of the present disclosure. In some examples, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some examples, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials in such a hybrid system may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some examples, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Throughout the following description, the terms “e-cigarette” and “electronic cigarette” may sometimes be used. However, it will be appreciated these terms may be used interchangeably with non-combustible aerosol (vapour) provision system or device as explained above.

In some examples, the present disclosure relates to consumables for holding aerosolgenerating material, and which are configured to be used with non-combustible aerosol provision devices. These consumables may be referred to as “articles” throughout the present disclosure.

The non-combustible aerosol provision system typically comprises a device part (also referred to herein as a “device”) and a consumable/article part (also referred to herein as an “article”). The device part typically comprises a power source and a controller. The power source may typically be an electrical power source, e.g. a rechargeable battery.

In some examples, the non-combustible aerosol provision system may comprise an area for receiving or engaging with the consumable/article, an aerosol generator (which may or may not be within the consumable/article), an aerosol generation area (which may be within the consumable/article), a housing, a mouthpiece, a filter, and/or an aerosol-modifying agent.

In some examples, the consumable/article for use with the non-combustible aerosol provision system may comprise aerosol-generating material, an aerosol-generating material storage area (also referred to herein as a reservoir for aerosolisable material), an aerosol-generating material transfer component (e.g. a wick, such as a pad), an aerosol generator (also referred to herein as an aerosol generating component), an aerosol generation area (also referred to herein as an aerosol generation chamber), a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

The systems described herein typically generate an inhalable aerosol by vaporisation of an aerosol generating material. The aerosol generating material may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. In some examples, the aerosol-generating material may comprise an “amorphous solid”, which may alternatively be referred to as a “monolithic solid” (i.e. non-fibrous). In some examples, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some examples, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid. The term “active substance” as used herein may relate to a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

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

The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

As used herein, the term “component” is used to refer to a part, section, unit, module, assembly or similar of an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly within an exterior housing or wall. An electronic cigarette may be formed or built from one or more such components, and the components may be removably or separably connectable to one another, or may be permanently joined together during manufacture to define the whole electronic cigarette. The present disclosure is applicable to (but not limited to) systems comprising two components separably connectable to one another and configured, for example, as a consumable/article component capable of holding an aerosol generating material (also referred to herein as a cartridge or cartomiser), and a device/control unit having a battery for providing electrical power to operate an element for generating vapour from the aerosol generating material.

Fig. 1 is a highly schematic diagram (not to scale) of an example non-combustible aerosol provision system such as an e-cigarette 10. The e-cigarette 10 has a generally cylindrical shape, extending along a longitudinal axis indicated by a dashed line, and comprises two main components, namely a control or power component or section 20 (which may be referred to herein as a device) and a cartridge assembly or section 30 (which may be referred to herein as an “article”, “consumable”, “cartomizer”, or “cartridge”) that operates as a vapour generating component. The cartridge assembly (or article) 30 includes a storage compartment (also referred to herein as a reservoir) 3 containing an aerosolisable material comprising (for example) a liquid formulation from which an aerosol is to be generated, for example containing nicotine. As an example, the aerosolisable material may comprise around 1 to 3% nicotine and 50% glycerol, with the remainder comprising roughly propylene glycol, and possibly also comprising other components, such as water or flavourings. The storage compartment 3 has the form of a storage tank, being a container or receptacle in which aerosolisable material can be stored such that the aerosolisable material is free to move and flow (if liquid) within the confines of the tank. Alternatively, the storage compartment 3 may contain a quantity of absorbent material such as cotton wadding or glass fibre which holds the aerosolisable material within a porous structure. The storage compartment 3 may be sealed after filling during manufacture so as to be disposable after the aerosolisable material is consumed, or may have an inlet port or other opening through which new aerosolisable material can be added. The cartridge assembly 30 also comprises an electrical aerosol generating component 4 located externally of the reservoir tank 3 for generating the aerosol by vaporisation of the aerosolisable material. In many examples, the aerosol generating component may be a heating element (heater) which is heated by the passage of electrical current (e.g. via resistive) to raise the temperature of the aerosolisable material until it evaporates. An aerosol generating material transfer component, e.g. liquid conduit arrangement such as a wick or other porous element (not shown), may be provided to deliver aerosolisable material from the storage compartment 3 to the aerosol generating component 4. The aerosol generating material transfer component may have one or more parts located inside the storage compartment 3 so as to be able to absorb aerosolisable material and transfer it by wicking or capillary action to other parts of the aerosol generating material transfer component that are in contact with the aerosol generating component 4. This aerosolisable material is thereby vaporised, and is to be replaced by new aerosolisable material transferred to the aerosol generating component 4 by the aerosol generating material transfer component.

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.

In some cases, the aerosol generating material transfer component (e.g. the conduit) for delivering liquid for vapour generation may be formed at least in part from one or more slots, tubes or channels between the storage compartment and the aerosol generating component which are narrow enough to support capillary action to draw source liquid out of the storage compartment and deliver it for vaporisation. In general, an atomiser can be considered to be an aerosol generating component able to generate vapour from aerosolisable material delivered to it, and an aerosol generating material transfer component (e.g. 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. Vapour produced by the aerosol generating component is driven off into this chamber, and as air passes through the chamber, flowing over and around the aerosol generating component, it collects the produced vapour whereby it condenses to form the required aerosol.

Returning to Fig. 1 , the cartridge assembly 30 also includes a mouthpiece 35 having an opening or air outlet through which a user may inhale the aerosol generated by the aerosol generating component 4, and delivered through the airflow channel.

The power component 20 includes a cell 5 (also referred to herein as a battery, and which may be re-chargeable) to provide power for electrical components of the e-cigarette 10, in particular the aerosol generating component 4. Additionally, there is a printed circuit board 28 and/or other electronics or circuitry for generally controlling the e-cigarette. The control electronics/circuitry connect the vapour generating element 4 to the battery 5 when vapour is required, for example in response to a signal from an air pressure sensor or air flow sensor (not shown) that detects an inhalation on the system 10 during which air enters through one or more air inlets 26 in the wall of the power component 20 to flow along the airflow channel. When the aerosol generating component 4 receives power from the battery 5, the aerosol generating component 4 vaporises aerosolisable material delivered from the storage compartment 3 to generate the aerosol, and this is then inhaled by a user through the opening in the mouthpiece 35. The aerosol is carried to the mouthpiece 35 along the airflow channel (not shown) that connects the air inlet 26 to the air outlet when a user inhales on the mouthpiece 35. An airflow path through the electronic cigarette is hence defined, between the air inlet(s) (which may or may not be in the power component) to the atomiser and on to the air outlet at the mouthpiece. In use, the air flow direction along this airflow path is from the air inlet to the air outlet, so that the atomiser can be described as lying downstream of the air inlet and upstream of the air outlet.

In this particular example, the power section 20 and the cartridge assembly 30 are separate parts detachable from one another by separation in a direction parallel to the longitudinal axis, as indicated by the solid arrows in Fig. 1. The components 20, 30 are joined together when the device 10 is in use by cooperating engagement elements 21 , 31 (for example, a screw, magnetic or bayonet fitting) which provide mechanical and electrical connectivity between the power section 20 and the cartridge assembly 30. This is merely an example arrangement, however, and the various components may be differently distributed between the power section 20 and the cartridge assembly section 30, and other components and elements may be included. The two sections may connect together end-to-end in a longitudinal configuration as in Fig. 1 , or in a different configuration such as a parallel, side- by-side arrangement. The system may or may not be generally cylindrical and/or have a generally longitudinal shape. Either or both sections may be intended to be disposed of and replaced when exhausted (the reservoir is empty or the battery is flat, for example), or be intended for multiple uses enabled by actions such as refilling the reservoir, recharging the battery, or replacing the atomiser. Alternatively, the e-cigarette 10 may be a unitary device (disposable or refillable/rechargeable) that cannot be separated into two or more parts, in which case all components are comprised within a single body or housing. Examples of the present invention are applicable to any of these configurations and other configurations of which the skilled person will be aware.

As mentioned, a type of aerosol generating component, such as a heating element, that may be utilised in an atomising portion of an electronic cigarette (a part configured to generate vapour from a source liquid) combines the functions of heating and liquid delivery, by being both electrically conductive (resistive) and porous. Note here that reference to being electrically conductive (resistive) refers to components which have the capacity to generate heat in response to the flow of electrical current therein. Such flow could be imparted by, for example, so-called resistive heating. An example of a suitable material for this is an electrically conductive material such as a metal or metal alloy formed into a sheet-like form, i.e. a planar shape with a thickness many times smaller than its length or breadth. Examples in this regard may be a mesh, web, grill and the like. The mesh may be formed from metal wires or fibres which are woven together, or alternatively aggregated into a non-woven structure. For example, fibres may be aggregated by sintering, in which heat and/or pressure are applied to a collection of metal fibres to compact them into a single porous mass. It is possible for the planar aerosol generating component to define a curved plane and in these instances reference to the planar aerosol generating component forming a plane means an imaginary flat plane forming a plane of best fit through the component.

These structures can give appropriately sized voids and interstices between the metal fibres to provide a capillary force for wicking liquid. Thus, these structures can also be considered to be porous since they provide for the uptake and distribution of liquid. Moreover, due to the presence of voids and interstices between the metal fibres, it is possible for air to permeate through said structures. Also, the metal is electrically conductive and therefore suitable for resistive heating, whereby electrical current flowing through a material with electrical resistance generates heat. Structures of this type are not limited to metals, however. Other conductive materials may be formed into fibres 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 vapour. Aerosol generation is thereby made very effective. In alternative examples, the aerosol generating component may be oriented within the chamber such that air flow though the chamber may flow in a direction which is substantially transverse to the surface direction, i.e. substantially orthogonally to the plane of the generally planar sheet-like aerosol generating component. An example of such a configuration can be found in WO2018/211252, the contents of which are incorporated herein in its entirety by reference.

The aerosol generating component may have, and/or be formed of, any one of the following structures: a woven or weave structure, mesh structure, fabric structure, open-pored fiber structure, open-pored sintered structure, open-pored foam or open-pored deposition structure. Said structures are suitable in particular for providing an aerosol generating component with a high degree of porosity. A high degree of porosity may ensure that the heat produced by the aerosol generating component is predominately used for evaporating the liquid and high efficiency can be obtained. A porosity of greater than 50% may be envisaged with said structures. In one embodiment, the porosity of the aerosol generating component is 50% or greater, 60% or greater, 70% or greater. The open-pored fiber structure can consist, for example, of a non-woven fabric which can be arbitrarily compacted, and can additionally be sintered in order to improve the cohesion. The open-pored sintered structure can consist, for example, of a granular, fibrous or flocculent sintered composite produced by a film casting process. The open-pored deposition structure can be produced, for example, by a CVD process, PVD process or by flame spraying. Open-pored foams are in principle commercially available and are also obtainable in a thin, fine-pored design. In one embodiment, the aerosol generating component is formed from a single layer. In one embodiment, the aerosol generating component has at least two layers, wherein the layers contain at least one of the following structures: a plate, foil, paper, mesh, woven structure, fabric, open-pored fiber structure, open-pored sintered structure, open-pored foam or open- 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 nonwoven metal fiber fabric. Individual layers are advantageously but not necessarily connected to one another by a heat treatment, such as sintering or welding. For example, the aerosol generating component can be designed as a sintered composite consisting of a stainless steel foil and one or more layers of a stainless steel wire fabric (material, for example AISI 304 or AISI 316). Alternatively, the aerosol generating component can be designed as a sintered composite consisting of at least two layers of a stainless steel wire fabric. The layers may be connected to one another by spot welding or resistance welding. Individual layers may also be connected to one another mechanically. For instance, a double-layer wire fabric could be produced just by folding a single layer. Instead of stainless steel, use may also be made, by way of example, of heating conductor alloys-in particular NiCr alloys and CrFeAl alloys ("Kanthal") which have an even higher specific electric resistance than stainless steel. The material connection between the layers is obtained by the heat treatment, as a result of which the layers maintain contact with one another-even under adverse conditions, for example during heating by the aerosol generating component and resultantly induced thermal expansions. Alternatively, the aerosol generating component may be formed from sintering a plurality of individual fibers together. Thus, the aerosol generating component can be comprised of sintered fibers, such as sintered metal fibers.

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

As described above, the aerosol generating component may be formed from a sintered metal fiber material and may be in the form of a sheet. Material of this sort can be thought of a mesh or irregular grid, and is created by sintering together a randomly aligned arrangement or array of spaced apart metal fibers or strands. A single layer of fibers might be used, or several layers, for example up to five layers. As an example, the metal fibers may have a diameter of 8 to 12 pm, arranged to give a sheet of thickness 0.16 mm, and spaced to produce a material density of from 100 g/m² to 1500 g/m², such as from 150 g/m² to 1000 g/m², 200 g/m² to 500 g/m², or 200 to 250 g/m², and a porosity of 84%. The sheet thickness may also range from 0.1 mm to 0.2mm, such as 0.1mm to 0.15mm. Specific thicknesses include 0.10 mm, 0.11 mm, 0.12mm, 0.13 mm, 0.14 mm, 0.15 mm 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 50mm. For example, the width and/or length of the vaporizer may be from 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm or 10 mm. The width may generally be smaller than the length of the aerosol generating component. It will be understood that the dimensions of the aerosol generating component may be varied.

Where the aerosol generating component is formed from an electrically resistive material, electrical current is permitted to flow through the aerosol generating component so as to generate heat (so called Joule heating). In this regard, the electrical resistance of the aerosol generating component can be selected appropriately. For example, the aerosol generating component may have an electrical resistance of 2 ohms or less, such as 1.8 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 aerosolisation. On the other hand, the resistance should not be so low so as to prejudice the integrity of the aerosol generator. For example, the resistance may not be lower than 0.5 ohms. The aerosol generating component may have a first electrical connector and a second electrical connector. The first electrical connector and the second electrical connector may be arranged at opposing ends of the aerosol generating component from each other. The electrical resistance may be between the first electrical connector and the second electrical connector. Each of the electrical connectors may be for connection to an electrical contact such that the aerosol generating component can be energised.

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.

A substantially planar aerosol generating component 100 for use as part of a noncombustible aerosol provision system is shown in Fig. 2. The aerosol generating component 100 comprises an aerosol generating portion 101 and two electrical connection portions 102, 103. Each electrical connection section 102, 103 is arranged at a respective end of the aerosol generating portion 101. The aerosol generating component 100 defines a longitudinal axis, which extends between the opposing ends of the aerosol generating portion 1. Each electrical connection portion 102, 103 comprises an aperture 104 for receiving an electrical contact 1000. Each aperture 104 may define a closed shape. Each electrical contact 1000 may be comprised by an article for use as part of the non-combustible aerosol provision system, and may be arranged in electrical communication with a power source. In use, when each electrical contact 1000 is received through a respective aperture 104, such that each electrical contact is connected to a respective electrical connection portion 102, 103, power can be delivered to the aerosol generating component 100 from the power source. In this way, the aerosol generating portion 101 can be heated to a temperature for aerosolising aerosolisable material. The aerosol generating portion 101 comprises a plurality of elongate apertures 105 (not all are numbered in Fig. 2), which are arranged in series, along the longitudinal axis of the aerosol generating component 100. Each elongate aperture 105 extends non-parallel (e.g. perpendicular) to the longitudinal axis of the aerosol generating component 100. A number of the elongate apertures 105 have an open end, and a number of the elongate apertures 105 define a closed shape. The aerosolisable material may be stored in an aerosol generating material transfer component arranged adjacent to or in contact with the aerosol generating component 100. The aerosol generating material transfer component may be comprised by the article. Each electrical contact 1000 may comprise (or be formed as) a cylindrical pin. The cylindrical pin 1000 may comprise a chamfered end-edge. This facilitates insertion of the cylindrical pin 1000 into the aperture

104.

To connect an electrical connection portion 102, 103 to a cylindrical pin 1000, the chamfered end edge of cylindrical pin 1000 in inserted through the aperture 104. The diameter of the cylindrical pin 1000 at the chamfered end edge is less than the diameter of the aperture 104, whereas the diameter at other portions of the cylindrical pin 1000 is slightly greater than the diameter of the aperture 104. Thus, when the cylindrical pin 1000 is inserted into the aperture

105, a section 102a, 103a of the electrical connection portion 102, 103 extending to a perimeter of the aperture 104, is biased against the outer surface of the cylindrical pin 1000. This forms the connection between each electrical connection portion 102, 103 and a cylindrical pin 1000.

The present inventors have discovered that the connection between the electrical connection portion 102, 103 and a cylindrical pin 1000 can result in deformation of not only each section 102a, 103a, but also other sections of each electrical connection portion 102, 103 and/or at least part of the aerosol generating portion 101. For example, as shown in Fig. 2, such a connection can result in inadvertent deformation of the electrical connection section 102, 103. This can in turn lead to inadvertent deformation of the aerosol generating portion 101. Such deformation can result in the formation of gaps and/or irregular spacing between the aerosol generating section 101 and an aerosol generating material transfer component. The provision of such gaps and/or spacing can reduce the contact area between the electrical connection section 102, 103 and the cylindrical pin 100, which may negatively affect the aerosol generation and/or the properties of the generated aerosol.

According to an aspect of the present disclosure, there is provided a substantially planar aerosol generating component 200 for use as part of a non-combustible aerosol provision system, the substantially planar aerosol generating component 200 comprising: an aerosol generating portion 201 ; and at least one electrical connection portion 202, 203 comprising an aperture 204 for receiving an electrical contact 1000, wherein at least one section 202a, 203a of the electrical connection portion 202, 203 extending to a perimeter of the aperture is predisposed to deformation.

Examples of the aerosol generating component 200 according to the present disclosure are shown in Figs. 4 to 8C. The present inventors have discovered that by virtue of the predisposition of the section 202a, 203a to deformation, the aerosol generating component 200 can be connected to an electrical contact 1000 whereby deformation of the adjacent section 202b, 203b is reduced or prevented. Therefore, in use, the aerosol generating component 200 according to the present disclosure can form improved contact with or improved regularity in spacing from an aerosol generating material transfer component. This can result in improved aerosol generation and/or improved aerosol properties.

The present inventors have further discovered that, in use, the connection between the electrical connection portion and the electrical contact can be such that disconnection of these components can damage or destroy the aerosol generating component. This provides a means of tamper-proofing an article in which the aerosol generating component is provided.

By “predisposed to deformation”, we mean the at least one section 202a, 203a is deformable to the extent that the at least one section 202a, 203a can be deformed by contact with an electrical contact (such as an electrical pin), e.g. during a manufacturing process, without causing damage to the aerosol generating component 200.

The at least one section 202a, 203a may be predisposed to resilient deformation. By “predisposed to resilient deformation”, we mean the at least one section 202a, 203a is resiliently deformable.

The at least one section 202a, 203a predisposed to deformation may be deformable relative to an adjacent section 202b, 203b of the aerosol generating component 100. The adjacent section 202b, 203b may be of the electrical connection portion, such as is shown in Figs. 4 to 8C. Alternatively, the adjacent section 202b, 203b may be of the aerosol generating portion 201 (e.g. if the electrical connection portion 202, 203 is entirely formed of a flexible material).

The at least one section 202a, 203a may be of increased flexibility relative to the adjacent section 202b, 203b. This may be achieved in various ways. For example, the at least one section 202a, 203 may be formed of a material which is inherently more flexible than the material of which the adjacent section 202a, 203a is formed.

The at least one section 202a, 203a may be of reduced thickness relative to the adjacent section 202b, 203b (see e.g. Figs. 4 to 8C). For example, the at least one section 202a, 203a may be at least 10% thinner than the adjacent section 202b, 203b. For example, the at least one section 202a, 203a may be at least 20% thinner than the adjacent section 202b, 203b. For example, the at least one section 202a, 203a may be at least 30% thinner than the adjacent section 202b, 203b. For example, the at least one section 202a, 203a may be at least 40% thinner than the adjacent section 202b, 203b. For example, the at least one section 202a, 203a may be at least 50% thinner than the adjacent section 202b, 203b. For example, the at least one section 202a, 203a may be at least 60% thinner than the adjacent section 202b, 203b.

The at least one section 202a, 203a may be separated by a line of weakness from the adjacent section 202b, 203b. The line of weakness may be created, for example, by using an instrument (e.g. a cutting means such as a knife) to score the line in the at least one electrical connection portion 202, 203.

In some aspects, the at least one section 202a, 203a is articulated to the adjacent section 202b, 203b. By “articulated”, we mean the at least one section 202a, 203a is connected to the adjacent section 202b, 203b by a flexible joint.

The perimeter of the aperture 204 may define a closed shape, such as is shown in Figs. 4 to 8C. The at least one section 202a, 203 may extend towards the centre of the aperture 204.

The at least one section 202a, 203a may comprise a plurality of sections 202a, 203a, wherein each of the sections 202a, 203a is predisposed to deformation (e.g. resilient deformation). Each of the sections 202a, 203a may be deformable relative to an adjacent section 202b, 203b of the aerosol generating component 100 (e.g. of the electrical connection portion 202, 203). The sections 202a, 203a may be spaced apart from each other. For example, in the aerosol generating component 200 of Figs. 4 to 8C, the at least one section 203a, 203b comprises four sections 203a, 203b, and the sections 203a, 203b are spaced apart from each other.

Referring to the aerosol generating component 200 of Figs. 4 to 8C, the aerosol generating component 200 may be integrally formed. That is, the aerosol generating component 200 may be formed from a single piece. In this way, the aerosol generating component 200 can be more efficient to manufacture and/or more robust than aerosol generating components formed of multiple pieces.

In some aspects, the aerosol generating section 201 is porous. This can permit more effective vaporisation of aerosolisable material.

In some aspects, the at least one section 202a, 203a may comprise at least one tab. For example, the at least one section 202a, 203 may comprise at least one tang, as shown in Figs. 4 to 8C. In some aspects, the at least one tab or tang may be offset with respect to the axis of the aerosol generating component 200. In some aspects, the at least one tab or tang may be angled with respect to the axis of the aerosol generating component 200. For example, the at least one tab or tang may be angled with respect to the axis of the aerosol generating component 200 by at least 3°. For example, the at least one tab or tang may be angled with respect to the axis of the aerosol generating component 200 by at least 4°. For example, the at least one tab or tang may be angled with respect to the axis of the aerosol generating component 200 by at least 5°. For example, the at least one tab or tang may be angled with respect to the axis of the aerosol generating component 200 by no greater than 10°. For example, the at least one tab or tang may be angled with respect to the axis of the aerosol generating component 200 by no greater than 8°. For example, the at least one tab or tang may be angled with respect to the axis of the aerosol generating component 200 by no greater than 7°. Offsetting or angling the tabs/tangs in this way has provided for aerosol generating components having a good resistance.

Referring to the aerosol generating component 200 of Figs. 4 to 8C, the aerosol generating portion 201 is an electrical resistance heater. Those skilled in the art will know that an “electrical resistance heater” generates heat by Joule heating. In this way, the aerosol generating portion 201 may comprise or be formed of an electrically resistive material. In some aspects, the aerosol generating component 200 comprises or is formed of an electrically resistive material.

The aerosol generating component 200 may define an axis. The axis may be a longitudinal axis. The axis may extend between respective ends of the aerosol generating component 200, such as is shown in e.g. Fig. 4. The aerosol generating component may comprise a plurality of (e.g. two) electrical connection sections 202, 203. Each electrical connection section 202, 203 may be as described herein. Each electrical connection section 202, 203 may be arranged at a respective end of the aerosol generating portion 201 .

The aerosol generating section 200 may comprise at least one (e.g. a plurality of) elongate apertures 205. For example, as shown in Fig. 4, the elongate apertures 205 may be arranged in series, along the axis of the aerosol generating component 200. Each elongate aperture 205 may extend non-parallel (e.g. perpendicular) to the axis of the aerosol generating component 200. As shown in Figs. 4 to 8C, a number of the elongate apertures 205 may have an open end, and a number of the elongate apertures 205 may define a closed shape. Other arrangements are also envisaged. For example, all of the elongate apertures 205 may have an open end, or all of the elongate apertures 205 may define a closed shape. The elongate apertures 205 can help to increase the resistance of the aerosol generating component 200 in use. In some aspect, such as shown in Fig. 4 to 8C, the aerosol generating component 200 may be formed from a single layer.

As described herein, the at least one electrical connection portion 202, 203 comprises an aperture 204 for receiving an electrical contact 1000. The or each electrical contact 1000 may be comprised by an article for use as part of the non-combustible aerosol provision system, and may be arranged in electrical communication with a power source. In use, when the or each electrical contact 1000 is received through a respective aperture 204, such that the or each electrical contact 1000 is connected to an electrical connection portion 202, 203, power can be delivered to the aerosol generating component 200 from the power source. In this way, the aerosol generating portion 201 can be heated to a temperature for aerosolising aerosolisable material. The aerosolisable material may be stored in an aerosol generating material transfer component arranged adjacent to or in contact with the aerosol generating component 200. The aerosol generating material transfer component may be comprised by the article.

Fig. 6 shows a side view of the aerosol generating component 200 prior to an electrical contact 1000 being inserted into the aperture 204 of the electrical connection portion 202,

203. Fig. 8A also shows this arrangement, but in close-up, perspective view of an electrical connection portion 202, 203. As shown in these figures, the sections 202a, 203a are in a non-deformed or non-biased state.

As shown in Figs. 7 to 8C, the electrical contact 1000 may comprise a cylindrical pin (see Figs. 7 to 8C). The cylindrical pin 1000 may comprise a chamfered end edge. This facilitates insertion of the cylindrical pin 1000 into the aperture 104. The electrical contact 1000 may be comprised by an article for use as part of a non-combustible aerosol provision system.

Before each electrical connection portion 202, 203 is connected to a respective cylindrical pin 1000, the aerosol generating portion 201 may be permanently deformed (e.g. by stamping or bending) to induce curvature in the aerosol generating portion 201 (see e.g. Figs. 8B and 8C).

With reference to Figs. 7 to 8C, to connect an electrical connection portion 202, 203 to the cylindrical pin 1000, the end edge of the cylindrical pin 1000 is inserted through the aperture

204. The diameter of the cylindrical pin 1000 at the chamfered end edge is less than the diameter of the aperture 204 (the distance between opposing sections 202a, 203a). By contrast the diameter of the cylindrical pin 1000 at other portions thereof is slightly greater than the diameter of the aperture 204. When the electrical contact 1000 is inserted into the aperture 204, the at least one section 202a, 203a is deformed relative to an adjacent section 202b, 203b. For example, when the electrical contact 1000 is inserted into the aperture 104, an outer surface of the electrical contact 1000 may urge the at least one section 202a, 203a outwardly and in the direction of insertion (the latter being indicated by upward arrows in Figs. 7, 8B, and 8C), wherein the at least one section 202a, 203a is resiliently biased against the outer surface of the electrical contact 1000. As shown in Figs. 7 to 8C, when the cylindrical pin 1000 is inserted into the aperture 104, the outer surface of the cylindrical pin 1000 urges the sections 202a, 203a outwardly and in the direction of insertion, wherein the sections 202a, 203a are resiliently biased against the outer surface of the cylindrical pin 1000.

A connection between the electrical connection portion 202, 203 and the electrical contact 1000 is thus formed. Thus, when the electrical contact 1000 is connected to the electrical connection portion 202, 203, the at least one section 202a, 203a is in a biased state. In the biased state, the at least one section 202a, 203a is biased (e.g. resiliently biased) against an outer surface of the electrical contact 1000. In the described arrangements, the aerosol generating component 200 forms a secure electrical connection with the electrical contact 1000, and inadvertent deformation of the aerosol generating component 200 is reduced or prevented.

In another aspect of the present disclosure, there is provided an article 30 for use as part of a non-combustible aerosol provision system 10, the article 30 comprising: a substantially planar aerosol generating component 200 comprising: an aerosol generating portion 201; and at least one electrical connection portion 202, 203 comprising an aperture 204 for receiving an electrical contact 1000, wherein at least one section 202a, 203a of the at least one electrical connection portion 202, 203 extending to a perimeter of the aperture 204 is predisposed to deformation; and at least one electrical contact 1000, wherein the at least one electrical contact 1000 is received through the aperture 204, such that the at least one electrical connection portion 202, 203 is connected (e.g. resiliently connected) to the at least one electrical contact 1000.

In one aspect, the at least one electrical connection portion 202, 203 comprises a plurality of (e.g. two) electrical connection portions 202, 203. In one aspect, the at least one electrical contact 1000 comprises a plurality of (e.g. two) electrical contacts 1000. In one aspect, an electrical contact 1000 is received through a respective aperture 204, such that each of the electrical connection portions 202, 203 is connected to a respective electrical contact 1000. In another aspect of the present disclosure, there is provided a non-combustible aerosol provision system 10 comprising: an article 30 comprising: a substantially planar aerosol generating component 200 comprising: an aerosol generating portion 201; and at least one electrical connection portion 202, 203 comprising an aperture 204 for receiving an electrical contact 1000, wherein at least one section 202a, 203a of the at least one electrical connection portion 202, 203 extending to a perimeter of the aperture 204 is predisposed to deformation; and an electrical contact 1000, wherein the at least one electrical contact 1000 is received through the aperture 204, such that the at least one electrical connection portion 202, 203 is connected (e.g. resiliently connected) to the at least one electrical contact 1000; a power source; and a controller.

In one aspect, the at least one electrical connection portion 202, 203 comprises a plurality of (e.g. two) electrical connection portions 202, 203. In one aspect, the at least one electrical contact 1000 comprises a plurality of (e.g. two) electrical contacts 1000. In one aspect, an electrical contact 1000 is received through a respective aperture 204, such that each of the electrical connection portions 202, 203 is connected to a respective electrical contact 1000.

Any aspect of the present disclosure may be defined in relation to any of the other aspects of the present disclosure. For example, one aspect of the present disclosure may include any of the features of any other aspect of the present disclosure and/or the features of one aspect of the present disclosure may be as defined in relation to the features of any other aspect of the present disclosure.

The figures herein are schematic and not drawn to scale. The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. A substantially planar aerosol generating component for use as part of a noncombustible aerosol provision system, the substantially planar aerosol generating component comprising: an aerosol generating portion; and at least one electrical connection portion comprising an aperture for receiving an electrical contact, wherein at least one section of the electrical connection portion extending to a perimeter of the aperture is predisposed to deformation.

2. A substantially planar aerosol generating component according to claim 1, wherein the at least on section predisposed to deformation is deformable relative to an adjacent section of the aerosol generating component.

3. A substantially planar aerosol generating component according to claim 2, wherein the adjacent section is of the at least one electrical connection portion.

4. A substantially planar aerosol generating component according to claim 2 or claim 3, wherein the at least one section predisposed to deformation is of increased flexibility relative to the adjacent section.

5. A substantially planar aerosol generating component according to any one of claims 2 to 4, wherein the at least one section predisposed to deformation is of reduced thickness relative to the adjacent section.

6. A substantially planar aerosol generating component according to any one of claims 2 to 5, wherein the at least one section predisposed to deformation is separated by a line of weakness from the adjacent section.

7. A substantially planar aerosol generating component according to any one of claims 2 to 6, wherein the at least one section predisposed to deformation is articulated to the adjacent section.

8. A substantially planar aerosol generating component according to any one of claims 1 to 7, wherein the at least one section is predisposed to resilient deformation.

9. A substantially planar aerosol generating component according to any one of claims 1 to 8, wherein the perimeter of the aperture defines a closed shape.

10. A substantially planar aerosol generating component according to any one of claims 1 to 9, wherein the at least one section predisposed to deformation comprises a plurality of sections, wherein each of the sections is predisposed to deformation relative to an adjacent section of the aerosol generating component.

11. A substantially planar aerosol generating component according to any one of claims 1 to 10, wherein the sections predisposed to deformation are spaced apart from each other.

12. A substantially planar aerosol generating component according to any one of claims 1 to 11 , wherein the substantially planar aerosol generating component is integrally formed.

13. A substantially planar aerosol generating component according to any one of claims 1 to 12, wherein the aerosol generating section is porous.

14. A substantially planar aerosol generating component according to any one of claims 1 to 13, wherein the at least one electrical connection portion comprises two electrical connection portions, each electrical connection portion being arranged at a respective end of the aerosol generating section.

15. A substantially planar aerosol generating component according to any one of claims 1 to 14, wherein the aerosol generating section comprises at least one elongate aperture.

16. A substantially planar aerosol generating component according to claim 15, wherein the at least one elongate aperture comprises a plurality of elongate apertures, optionally wherein the elongate apertures are arranged in series along an axis of the aerosol generating component, optionally wherein each of the elongate apertures extends nonparallel to an axis of the aerosol generating component.

17. A substantially planar aerosol generating component according to any one of claims 1 to 16, wherein the substantially planar aerosol generating component is formed from a single layer.

18. An article for use as part of a non-combustible aerosol provision system, the article comprising: a substantially planar aerosol generating component comprising: an aerosol generating portion; and at least one electrical connection portion comprising an aperture for receiving an electrical contact, wherein at least one section of the at least one electrical connection portion extending to a perimeter of the aperture is predisposed to deformation; and at least one electrical contact, wherein the at least one electrical contact is receivable through the aperture, such that the at least one electrical connection portion can be connected to the at least one electrical contact.

19. A non-combustible aerosol provision system comprising: an article comprising: a substantially planar aerosol generating component comprising: an aerosol generating portion; and at least one electrical connection portion comprising an aperture for receiving an electrical contact, wherein at least one section of the at least one electrical connection portion extending to a perimeter of the aperture is predisposed to deformation ; and at least one electrical contact, wherein the electrical contact is receivable through the aperture, such that the at least one electrical connection portion can be connected to the at least one electrical contact; a power source; and a controller.

20. An article according to claim 18 or a system according to claim 19, wherein the substantially planar aerosol generating component is characterised according to any one of claims 1 to 17.