GB2617310A

GB2617310A - Provision system

Info

Publication number: GB2617310A
Application number: GB2118827.1A
Authority: GB
Inventors: Sheridan James; Rothwell Howard; daniels Christopher
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-12-22
Filing date: 2021-12-22
Publication date: 2023-10-11

Abstract

An atomiser for use in a non-combustible aerosol provision system comprises: a first carrier component 101; a second carrier component 102; and a substantially planar aerosol generating component 103 arranged between the first and second carrier components 101, 102, wherein the first and second carrier components 101, 102 are connected. The connection may be one or more of: snap fit, press fit; and interference fit, and/or one of the carrier components 101, 102 may comprise at least one engaging element 111, 112 configured to engage with the other component 101, 102, wherein the at least one engaging element 111, 112 may comprise a projection, such as a resiliently flexible projection and/or a retaining portion. The first and second carrier components 101, 102 may be connected together to retain the substantially planar aerosol generating component 103, and/or to bias the substantially planar aerosol generating component 103 against one or more electrical contacts of the atomiser. An airflow path may be provided between the first and second carrier components 101, 102, substantially parallel to the plane of the aerosol generating component 103. The aerosol generating component 103 may be formed from a porous material.

Description

Provision System

Field

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

Background

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

These characteristics can include the size of the particles of the aerosol, the total amount of the aerosol produced, etc. Where the aerosol delivery system is used to simulate a smoking experience, e.g. as an e-cigarette or similar product, control of these various characteristics is especially important since the user may expect a specific sensorial experience to result from the use of the system.

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

Summary

According to a first aspect of the present disclosure, there is provided an atomiser for use in a non-combustible aerosol provision system, the atomiser comprising: a first carrier component; a second carrier component; and a substantially planar aerosol generating component; wherein the first carrier component and the second carrier component are connected together.

The first carrier component and the second carrier component may be connected together by one or more of: a snap fit, a press fit, and an interference fit.

One of the first carrier component and the second carrier component may comprise at least one engaging element configured to engage with the other of the first carrier component and the second carrier component.

One of the first carrier component and the second carrier component may comprise a plurality of engaging elements configured to engage with the other of the first carrier component and the second carrier component.

Where there is a plurality of engaging elements, the engaging elements may be configured to engage with opposing sections of the other of the first carrier component and the second carrier component. The opposing sections may be opposing ends or sides.

Where there is a plurality of engaging elements, the engaging elements may comprise at least one pair of engaging elements, each pair being configured to engage with opposing sections of the other of the first carrier component and the second carrier component.

Where there is a plurality of engaging elements, the engaging elements may be arranged in the same plane as each other. The plane in which the engaging elements are arranged may be substantially parallel to the substantially planar aerosol generating component.

The or each engaging element may comprise a projection. The projection may be resiliently flexible.

The or each engaging element may comprise a retaining portion for retaining the other of the first carrier component and the second carrier component. The retaining portion may latch over at least part of the other of the first carrier component and the second carrier component.

The or each engaging element may comprise a ramp portion. The ramp portion may comprise a curved outer surface and/or an angled outer surface.

The or each engaging element may be configured to resiliently retain the other of the first carrier component and the second carrier component.

The first carrier component and the second carrier component may be connected together (e.g. by one or more of: a snap fit, a press fit, and an interference fit) to retain (e.g. resiliently retain) the substantially planar aerosol generating component.

The first carrier component and the second carrier component may be connected together (e.g. by one or more of: a snap fit, a press fit, and an interference fit) to bias the substantially planar aerosol generating component against one or more electrical contacts of the atomiser.

The first carrier component and the second carrier component may together provide an airflow path.

The airflow path may be provided between the first carrier component and the second carrier component.

The airflow path may comprise an aerosol generation chamber.

The substantially planar aerosol generating component may be at least partly located within the airflow path.

The substantially planar aerosol generating component may be at least partly located within the aerosol generation chamber.

The airflow path may be substantially parallel to the plane of the substantially planar aerosol generating component.

The first carrier component may be of a generally planar form.

The second carrier component may be of a generally planar form.

The first carrier component, the second carrier component, and the substantially planar aerosol generating component may be aligned in substantially parallel planes.

The first carrier component and the second carrier component may be spaced apart so as to define a capillary gap between the first carrier component and the second carrier component. In this way, aerosolisable material can be fed to the aerosol generating component through the capillary gap.

In some examples, the aerosol generating component is formed from a porous material.

In some examples, the aerosol generating component is formed from an electrically conductive material.

In some examples, the aerosol generating component is formed from a woven or weave structure, mesh structure, fabric structure, open-pored fiber structure, open-pored sintered structure, open-pored foam or open-pored deposition structure.

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

The article may comprise a housing. The atomiser may be provided within the housing.

The article may comprise a reservoir for aerosolisable material.

The article may comprise a mouthpiece.

According to a third aspect of the present disclosure, there is provided a noncombustible aerosol provision system comprising: an article comprising an atomiser according to the first aspect of the present disclosure-and a device comprising one or more of a power source and a controller.

According to a fourth aspect of the present disclosure, there is provided a method of manufacturing an atomiser, the method comprising: providing an first carrier component, a second carrier component, and a substantially planar aerosol generating component; arranging the substantially planar aerosol generating component between the first carrier component and the second carrier component; and connecting together the first carrier component and the second carrier component.

The features as defined in relation to the first aspect of the present disclosure are equally applicable to the other aspects of the present disclosure. For example, the atomiser of the third aspect of the present disclosure (including any of its features) may be as defined according to the first aspect of the present disclosure.

Brief Description of the Drawings

Various embodiments will now be described in detail by way of example only with reference to the accompanying drawings in which: Fig. 1 is a schematic diagram of an example non-combustible aerosol provision system according to the present disclosure.

Fig. 2 is a perspective view of an atomiser for use in a non-combustible aerosol provision system according to the present disclosure (comprising an end cap).

Fig. 3 is a perspective view of the atomiser of Fig. 2 (without the end cap).

Fig. 4 is perspective view of the first carrier component and the aerosol generating component of the atomiser of Fig. 2.

Fig. 5 is a rear view of the first carrier component of the atomiser of Fig. 2.

Fig. 6 is a schematic example of the first carrier component and the second carrier component of the atomiser of Fig. 2 (the aerosol generating component is not shown).

Fig. 7 is a schematic example of the first carrier component and the second carrier component of the atomiser of Fig. 2 (the aerosol generating component is not shown).

Fig. 8 is a schematic example of the first carrier component and the second carrier component of the atomiser of Fig. 2 (the aerosol generating component is not shown).

Figs. 9A-C schematically show a method of manufacturing the atomiser of Fig. 2 (the aerosol generating component is not shown).

Fig. 10 schematically shows a method of manufacturing the atomiser of Fig. 2.

Figs. 11A-E show an alternative atomiser for use in a non-combustible aerosol provision system according to the present disclosure.

Detailed Description

Aspects and features of certain examples and embodiments are discussed/described herein. Some aspects and features of certain examples and embodiments may be implemented conventionally and these are not discussed/described in detail in the interests of brevity. It will thus be appreciated that aspects and features of apparatus and methods discussed herein which are not described in detail may be implemented in accordance with any conventional techniques for implementing such aspects and features.

As described above, the present disclosure relates to (but is not limited to) noncombustible aerosol provision systems and devices that generate an aerosol from an aerosol-generating material (which also may be referred to herein as aerosolisable material) without combusting the aerosol-generating material. Examples of such systems include electronic cigarettes, tobacco heating systems, and hybrid systems (which generate aerosol using a combination of aerosol-generating materials). In some examples, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement of the present disclosure. In some examples, the non-combustible aerosol provision system is an aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some examples, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials in such a hybrid system may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some examples, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

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

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

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

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

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

The systems described herein typically generate an inhalable aerosol by 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°/o or 70wt°/o of amorphous solid, to about 90wr/o, 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 nutraceuficals, 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, myrisfic 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 a non-combustible aerosol provision system such as an electronic cigarette or similar device that incorporates several smaller parts or elements, possibly within an exterior housing or wall. An electronic cigarette may be formed or built from one or more such components, and the components may be removably or separably connectable to one another, or may be permanently joined together during manufacture to define the whole electronic cigarette. The present disclosure is applicable to (but not limited to) systems comprising two components separably connectable to one another and configured, for example, as a consumable/article component capable of holding an aerosol generating material (also referred to herein as a cartridge or 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/vapour provision system such as an e-cigarette 10. The e-cigarette 10 may have a generally cylindrical shape, extending along a longitudinal axis indicated by a dashed line, and comprises two main components, namely a control or power component or section 20 (which also may be referred to herein as a device) and a cartridge assembly or section 30 (which also may be referred to herein as an article, consumable, cartomizer, or cartridge) that operates as a vapour generating component.

The cartridge assembly 30 includes a storage compartment 3 (which also may be referred to herein as a reservoir) 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 (or reservoir) 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 a substantially planar aerosol generating component 4 (which may be electrical) located externally of the reservoir tank 3 for generating the aerosol by vaporisation of the aerosolisable material. In many devices, the aerosol generating component may be a heating element (heater) which is heated by the passage of electrical current (via resistive or inductive heating) to raise the temperature of the aerosolisable material until it evaporates. A liquid conduit arrangement such as a wick or other porous element (not shown) may be provided to deliver aerosolisable material from the storage compartment 3 to the aerosol generating component 4. The wick may have one or more parts located inside the storage compartment 3 so as to be able to absorb aerosolisable material and transfer it by wicking or capillary action to other parts of the wick that are in contact with the vapour generating element 4. This aerosolisable material is thereby vaporised, to be replaced by new aerosolisable material transferred to the vapour generating element 4 by the wick.

A heater and wick combination, or other arrangement of parts that perform the same functions, is sometimes referred to as an atomiser or atomiser assembly. Various designs are possible, in which the parts may be differently arranged compared to the highly schematic representation of Fig. 1. For example, the wick may be an entirely separate element from the aerosol generating component, or the aerosol generating component may be configured to be porous and able to perform the wicking function directly (by taking the form of a suitable electrically resistive mesh or capillary body, for example).

In some cases, the conduit for delivering liquid for vapour generation may be formed at least in part from one or more slots, tubes or channels between the storage compartment and the aerosol generating component which are narrow enough to support capillary action to draw source liquid out of the storage compartment and deliver it for vaporisation. In general, an atomiser can be considered to be an aerosol generating component able to generate vapour from aerosolisable material delivered to it, and a liquid conduit (pathway) able to deliver or transport liquid from a storage compartment or similar liquid store to the aerosol generating component by a capillary force.

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 126 having an opening or air outlet through which a user may inhale the aerosol generated by the aerosol generating component 4, and delivered through the airflow channel.

The power component 20 includes a cell or battery 5 (which also may be referred to herein 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 Figure 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 Figure 1, or in a different configuration such as a parallel, side-by-side arrangement. The system may or may not be generally cylindrical and/or have a generally longitudinal shape. Either or both sections may be intended to be disposed of and replaced when exhausted (the reservoir is empty or the battery is flat, for example), or be intended for multiple uses enabled by actions such as refilling the reservoir, recharging the battery, or replacing the atomiser. Alternatively, the e-cigarette 10 may be a unitary device (disposable or refillable/rechargeable) that cannot be separated into two or more parts, in which case all components are comprised within a single body or housing. Embodiments and examples of the present invention are applicable to any of these configurations and other configurations of which the skilled person will be aware.

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

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 l0 ceramic materials, which may or may not be doped with substances intended to tailor the physical properties of the mesh.

A planar sheet-like porous aerosol generating component of this kind can be arranged within an electronic cigarette such that it lies within the aerosol generating chamber forming part of an airflow channel. The aerosol generating component may be oriented within the chamber such that air flow though the chamber may flow in a surface direction, i.e. substantially parallel to the plane of the generally planar sheet-like aerosol generating component. An example of such a configuration can be found in W02010/045670 and W02010/045671, the contents of which are incorporated herein in their entirety by reference. Air can thence flow over the aerosol generating component, and gather vapour. Aerosol generation is thereby made very effective. In alternative examples, the aerosol generating component may be oriented within the chamber such that air flow though the chamber may flow in a direction which is substantially transverse to the surface direction, i.e. substantially orthogonally to the plane of the generally planar sheet-like aerosol generating component. An example of such a configuration can be found in W02018/211252, the contents of which are incorporated herein in its entirety by reference.

The aerosol generating component may have 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 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 0.1mm to 0.2mm, such as 0.1mm to 0.15mm. Specific thicknesses include 0.10 mm, 0.11 mm, 0.12mm, 0.13 mm, 0.14 mm, 0.15 mm 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.

Where the aerosol generating component is formed from an electrically resistive material, electrical current is permitted to flow through the aerosol generating component so as to generate heat (so called Joule heating). In this regard, the electrical resistance of the aerosol generating component can be selected appropriately. For example, the aerosol generating component may have an electrical resistance of 2 ohms or less, such as 1.8ohms or less, such as 1.7ohms or less, such as 1.6ohms or less, such as 1.5ohms or less, such as 1.4ohms or less, such as 1.3ohms or less, such as 1.2ohms or less, such as 1.1ohms or less, such as 1.0ohm or less, such as 0.9ohms or less, such as 0.8ohms or less, such as 0.7ohms or less, such as 0.6ohms or less, such as 0.5ohms or less. The parameters of the aerosol generating component, such as material, thickness, width, length, porosity etc. can be selected so as to provide the desired resistance. In this regard, a relatively lower resistance will facilitate higher power draw from the power source, which can be advantageous in producing a high rate of aerosolizafion. On the other hand, the resistance should not be so low so as to prejudice the integrity of the aerosol generator. For example, the resistance may not be lower than 0.5 ohms.

Planar aerosol generating components, such as heating elements, suitable for use in systems, devices and articles disclosed herein may be formed by stamping or cutting (such as laser cutting) the required shape from a larger sheet of porous material. This may include stamping out, cutting away or otherwise removing material to create openings in the aerosol generating component. These openings can influence both the ability for air to pass through the aerosol generating component and the propensity for electrical current to flow in certain areas. Fig. 2 shows an exemplary atomiser 100 for use in a non-combustible aerosol/vapour provision system 10, according to the present disclosure. In general terms, the atomiser 100 comprises a first carrier component 101; a second carrier component 102; and a substantially planar aerosol generating component 103 (only partially visible in Figure 2). The first and second carrier components 101, 102 play a role in supporting the substantially planar aerosol generating component 103. Thus, for convenience, and having regard to the orientation represented in the Figures, the first and second carrier components 101, 102 also may be considered as a lower cradle component 101 and an upper cradle component 102. The first and second carrier components 101, 102 are separated by a distance d (shown in Figures 6 to 8). This separation provides a gap through which aerosolisable material can be fed to the aerosol generating component 103 in use. The gap provides a capillary channel (one each side) which extends along both sides of the aerosol generating component 103.

The first carrier component 101 and the second carrier component 102 are connected together. By "connected together it is meant that the first and second carrier components 101, 102 (which together form a carrier assembly or a cradle assembly) are secured in position relative to each other. In other words, by "connected together" it is meant there is engagement between the two components which resists their separation. The connection may be releasable (by application of certain force) or non-releasable (meaning that destruction of one or both components is required for their separation). This is distinct from the situation where they are solely mounted to one another. In this way, the carrier components 101, 102 are less prone to becoming dislodged and/or separated, and the distance between the carrier components 101, 102 can be maintained (kept approximately constant). This is an improvement over atomisers having first and second carrier components that are mounted but not connected together. The first and second carrier components of such atomisers may easily become separated and/or dislodged, e.g. by a sudden movement or impact. This can negatively affect the functionality of the atomiser. For example, leakage of aerosolisable material can occur. Moreover, the distance between the carrier components may be increased and thus the gap through which aerosolisable material can be fed to the aerosol generating component can become widened, causing a greater quantity of aerosolisable material than intended to flow onto the aerosol generating component and thus the atomiser to malfunction. Connecting the carrier components 101, 102 together provides a solution to these problems.

In some embodiments, the first carrier component 101 and the second carrier component 102 are connected together by one or more of: a snap fit, a press fit, and an interference fit. Such types of connection mean that the atomiser 100 can be efficiently manufactured (in terms of cost and time), without the requirement of external fastening means for holding the carrier components 101, 102 together. Moreover, such types of connection mean that the atomiser 100 can be provided in a compact form, which is particularly beneficial in the context of an aerosol provision system 10. Furthermore, such types of connection result in the provision of an atomiser 100 that can be more reliable than an atomiser having external fastening means.

In the embodiment of Fig. 2, the aerosol generating component 103 is a substantially planar, electrically conductive heating element 103.

In the embodiment of Fig. 2, and as shown in Figure 5, the atomiser 100 comprises a first electrical contact element 115 for connecting to a first end of the aerosol generating component 103 and a second electrical contact element 116 for connecting to a second end of the aerosol generating component 103. The first and second electrical contact elements 115, 116 may be formed of a sheet metal material, for example comprising metallic strips formed into an appropriate shape having regard to the shape and configuration of the other elements of the apparatus in accordance with conventional manufacturing techniques, or may comprise conventional flexible wiring. In embodiments where electrical energy is inductively coupled to the aerosol generating component it will be understood that such contact elements are not required. The first and second carrier components 101, 102 may be moulded from a plastics material having a high glass fibre content (e.g. at or great than around 50%) to provide improved rigidity and resistance to high temperatures, for example temperatures around 230 degrees centigrade.

In the embodiment of Fig. 2, the first and second carrier components 101, 102 are broadly speaking of a generally planar, rectangular form (although with variations in size and shape along their lengths as discussed further below). Each carrier component 101, 102 is provided with a recess 119 (only visible for first carrier component 101 in Fig. 4) running along its length on an inner face so that when the two carrier components 101, 102 are brought together to sandwich the aerosol generating component 103 as discussed further below, they form a carrier assembly (or a cradle assembly) having a generally rectangular prismatic configuration with an airflow path 110 (defined by the respective recesses 119) running down the interior of the carrier assembly and in which the aerosol generating component 103 is disposed. The airflow path 110 formed by the two recesses 119 comprises the aerosol generation chamber of the atomiser 100. The carrier assembly need not take on an elongate form, but may have width and length dimensions that are similar. Moreover, the dimensions of the respective recesses 119 may be varied.

In the embodiment of Fig. 2, as shown in Figure 4, the first carrier component 101 is of a generally planar, rectangular form and has an upstream portion 104, a downstream portion 105, and two side edges 106. The first carrier component 101 and the second carrier component 102 have substantially the same width (side edge to side edge). The recess 119 running along the length of the first carrier component 101 extends between an inlet 113 on the upstream portion 104 and an outlet 114 on the downstream portion 105.

One of the first carrier component 101 and the second carrier component 102 may comprise at least one engaging element 111, 112 configured to engage with the other of the first carrier component 101 and the second carrier component 102. The engaging elements 111, 112 help further secure the connection between the first and second carrier components 101, 102.

The first carrier component 101 and the second carrier component 102 may comprise a plurality (e.g. 2, 4, 6 or more) of engaging elements 111, 112 configured to engage with the other of the first carrier component 101 and the second carrier component 102. For example, the engaging elements 111, 112 may be arranged to engage with opposing sections (e.g. ends or sides) of the other of the first carrier component 101 and the first carrier component 102. Engaging and thus retaining the opposing sections further reduces the risk of separation of the first and second carrier components 101, 102. In some embodiments, the engaging elements 111, 112 comprise at least one pair of engaging elements 111, 111 and 112, 112, each pair being configured to engage with opposing sections (e.g. ends or sides) of the other of the first carrier component 101 and the second carrier component 102.

In the embodiment of Fig. 2, as shown in Figure 3, the first carrier component 101 comprises four engaging elements 111, 112. Two of the engaging elements 111, 112 are provided on the upstream portion 104, and two of the engaging elements 111, 112 are provided on the downstream portion 105. The engaging elements 111, 112 are arranged in two pairs, with one pair corresponding to an engaging element 111 on the upstream portion 104 and an engaging element 111 on the downstream portion 105, and the other pair corresponding to the other engaging element 112 on the upstream portion 104 and the other engaging element 112 on the downstream portion 105. By using pairs of engaging elements 111, 112, the first and second carrier components 101, 102 can be connected so as to be substantially immovable with respect to each other. In this particular embodiment, the engaging elements 111, 112 are provided on either side of the recess 119 of the first carrier component 101. The engaging elements 111, 112 are arranged in the same plane as each other, which is substantially parallel to the substantially planar aerosol generating component 103. It will be appreciated that the number, form and location of the engaging elements 111, 112 may be varied. For example, in some embodiments, the engaging elements 111, 112 may be configured to engage opposing sides of the other of the first carrier component 101 and the second carrier component 102.

The precise form of the engaging elements 111, 112 may be varied. What is important is that the engaging elements 111, 112 (or element) engage with the other of the first carrier component 101 and the second carrier component 102, such that the carrier components 101, 102 are connected together. In some embodiments, the or each engaging element 111, 112 is configured to resiliently retain the other of the first carrier component 101 and the second carrier component 102. In this way, the engaging elements 111, 112 can grip the other of the first carrier component 101 and the second carrier component 102. This facilitates a particularly secure connection between the carrier components 101, 102.

In the embodiment of Fig. 2, as shown in Figure 4, each of the engaging elements 111, 112 comprises a resiliently flexible projection 111A, 112A. Whilst it is not essential for the projection 111A, 112A to be resiliently flexible, resilient flexibility helps with assembly of the carrier components 101, 102, and to connect the carrier components 101, 102 together in a particularly secure fashion (as described below). In the embodiment of Fig. 2, the projections 111A, 112A upwardly extend orthogonal to the plane of the first carrier component 101 (see e.g. Figs. 6 and 7). However, in other embodiments, the orientation of the projections 111A, 112A may be varied. For example, as shown in Fig. 8, each projection 111A, 112A may form an oblique angle with respect to the plane of the first carrier component 101.

The or each engaging element 111, 112 may comprise a retaining portion 1116, 1126 (e.g. a retaining shoulder) for retaining the other of the first carrier component 101 and the second carrier component 102. The retaining portion(s) 111B, 1126 function as a barrier that prevents separation of the first and second carrier components 101, 102 from each other. For example, the retaining portion 1116, 1126 may latch over at least part of the other of the first carrier component 101 and the second carrier component 102. The retaining portion(s) 1118, 1128 may be provided in various forms, e.g. as shown in Figs. 6-8. For example, the retaining portion(s) 111B, 1128 may extend generally inwardly, in the plane of the of the first carrier component 101 (or second carrier component 102 if it is provided thereon). The particular angle that the retaining portion(s) 1118, 1128 forms with the projection 111A, 112A can be varied (e.g. orthogonal or oblique).

The or each engaging element 111, 112 may comprise a ramp portion 111C, 112C. The ramp portion may comprise a curved and/or angled outer surface 111C, 112C. This can help with assembly of the carrier components 101, 102, as is explained in detail below. In the embodiment of Fig. 2 (see also Fig. 6), each engaging element 111, 112 comprises a ramp portion in the form of curved outer surface 111C, 112C, which slopes (inwardly and downwardly) from the projection 111A, 112A to an edge of the retaining portion 111B, 112B. The ramp portion 111C, 112C may be provided in various forms (e.g. curved and/or angled and/or of varying dimensions), e.g. as shown in Figs. 6-8.

With reference to Fig. 5, the first carrier component 101 comprises respective upstream and downstream gaps 117, 118 for receiving the respective electrical contact elements 115, 116.

Specifically, one of the gaps 117 is provided towards an upstream corner of the first carrier component 101; and the other of the gaps 118 is provided towards a diagonally opposed downstream corner of the first carrier component 101. It will be appreciated that the precise form and position of the electrical contact elements 115, 116 can be varied.

In the embodiment of Fig. 2, the second carrier component 102 has an upstream edge 107, a downstream edge 108, and two side edges 109. In some embodiments, the distance between the ends of the second carrier component 102 (e.g. the edges 107, 108) is less than the distance between the projections 111A, 112A of each pair of engaging elements 111, 111, but greater than the distance between the retaining portions 111B, 112C of each pair of engaging elements 111, 112. Such an arrangement facilitates a particularly secure connection between the first and second carrier components 101, 102.

It is also envisaged that the first carrier component 101 and the second carrier component 102 may be connected together to retain the substantially planar aerosol generating component 103. This may be achieved in various ways. For example, at least part of the first carrier component 101 and/or at least part of the second carrier component 102 may be configured to contact (e.g. urge against) the substantially planar aerosol generating component 103.

The substantially planar aerosol generating component 103 may be formed from a sintered metal fibre material and is generally in the form of a sheet. It will be appreciated that other porous conducting materials may equally be used. In this particular example, the substantially planar aerosol generating component 103 comprises a main portion 103A with electrical contact extensions 103B at each end for connecting to the respective electrical contact elements 115, 116. In the embodiment of Fig. 2, the main portion 103A of the aerosol generating component is generally rectangular with a longitudinal dimension (i.e. in a direction running between the electrical contact extensions 103B) of around 20 mm, and a width of around 8 mm.

For example, the length by width dimensions of the aerosol generating component 103 may be 16 mm by 8 mm, or 11 mm by 3 mm, or 28 mm by 11 mm, or 5 mm by 2 mm. It will appreciate that the dimensions may be varied.

In the embodiment of Fig. 2, the longitudinal dimension corresponds to the direction of airflow through the vaporisation chamber (note that in other examples, the longitudinal dimension need not be the longest dimension of the aerosol generating component). The thickness of the sheet comprising the aerosol generating component 103 may be varied (e.g. in this example it is around 0.15 mm). As can be seen in Fig. 4, the generally-rectangular main portion 103A of the aerosol generating component 103 has a plurality of openings in the form of slots extending inwardly from each of the longer sides (sides parallel to the longitudinal direction). In this specific embodiment, the slots extend inwardly by around 4.8 mm and have a width of around 0.6 mm. In this specific embodiment, the slots extending inwardly are separated from one another by around 5.4 mm on each side of the aerosol generating component 103 with the slots extending inwardly from the opposing sides being offset from one another by around half this spacing. It will appreciate that the dimensions may be varied.

In other words, the slots are alternately positioned along the longitudinal sides. A consequence of this arrangement of slots in the aerosol generating component 103 is that current flow along the aerosol generating component 103 is in effect forced to follow a meandering path which results in a concentration of current, and hence electrical power, around the ends of the slots. In this regard, and due to the presence of the slots, the aerosol generating component 103 has been constructed such that some areas of the aerosol generating component 103 On this example the meandering path) have a greater propensity for current flow than others.

By having current follow a meandering path, a greater number of high temperature areas (also referred to as "hot spots") are more evenly distributed across the aerosol generating component 103, relative to having current follow a direct path which provides fewer, larger high temperature areas that are less evenly distributed across the aerosol generating component 103. In this way, the risk of burning of aerosolisable material and/or inadvertent drying out of the aerosol generating component 103 can be reduced. Also, more even heat distribution and thus more consistent aerosolisafion (e.g. a more consistent particle size) can be achieved.

In some examples (e.g. see Fig. 4), the aerosol generating component 103 is rotationally symmetrical about an axis through the centre of, and perpendicular to, the plane of the aerosol generating component 103.

The atomiser 100 may be provided with an end cap 200, as shown in Figure 2. However, it will be appreciated that the end cap 200 may not be part of the atomiser 100. For example, the end cap 200 may be part of an article for use in the aerosol provision system 10. In the embodiment of Fig. 2, the end cap includes a sleeve portion 201 and a base portion 202, which are integrally formed. The sleeve portion 201 projects upwardly from, and is surrounded by, the base portion 202, which projects radially outwardly from the sleeve portion 201. In this way, the sleeve portion 201 is concentrically surrounded by the base portion 202. The sleeve portion 201 defines a space in which the upstream portion 104 of the first carrier component 101 can be slidably received and retained.

The atomiser 100 may be manufactured in various ways. Broadly speaking, the method of manufacturing the atomiser 100 comprises: providing an first carrier component 101, a second carrier component 102, and a substantially planar aerosol generating component 103; arranging the substantially planar aerosol generating component 103 between the first carrier component 101 and the second carrier component 102; and connecting together the first carrier component 101 and the second carrier component 102.

A specific example of such a method is described below. As shown in Figs. 5 and 10, the electrical contact elements 115, 116 are mounted to the first carrier component 101. This is achieved, for example, by snap fitting one of the electrical contact elements 115 onto the lower surface of the first carrier component 101, between the edge of the upstream portion 104 towards one of the side edges 106, and the upstream gap 117, such that a portion of the electrical contact element 115 projects through the downstream gap 117; and snap fitting the other electrical contact 116 onto the underside of the first carrier component 101, between the edge of the upstream portion 104 towards the other of the side edges 106, and the downstream gap 118, such that a portion of the electrical contact element 116 projects through the upstream gap 118. The precise manner in which the electrical contact elements 115, 116 are fitted to the first carrier component 101 may be varied. Connecting (rather than only mounting) the electrical contact elements 115, 116 to the first carrier component 101 prevents the electrical contact elements 115, 116 from becoming dislodged.

With regard to Fig. 9A, the first carrier component 101 is arranged with its engaging elements 111, 112 upwardly facing. The aerosol generating component 103 is arranged onto the first carrier component 101 in the space between the upstream and downstream projections 111A, 112A (not shown in Figs. 9A-C). This can be achieved in various ways. For example, the aerosol generating component 103 may be slid into the space (side-by side with the first carrier component 101). Alternatively, the aerosol generating component 103 may be lowered into the space (face-to-face) with the first carrier component 101). As a result, one of the electrical contact extensions 103B of the aerosol generating component 103 contacts the portion of the electrical contact element 115 projecting through the upstream gap 117, and the other electrical contact extension 103B of the aerosol generating component 103 contacts the portion of the electrical contact 116 projecting through the downstream gap 118. In the embodiment of Fig. 2, the electrical contact extensions 103B abut the electrical contacts 115, 116. However, in other embodiments, the electrical contact extensions 103B and the electrical contacts 115, 116 may be connected together, e.g. by welding or adhesive means.

In the embodiment of Fig. 2, the first carrier component 101 comprises a plurality of locating slats 120 for locating the aerosol generating component 103 on the first carrier component 101 (see Fig 4). The locating slats 120 are provided on an upper surface of the first carrier component 101 and align with the slots in the aerosol generating component 103. Although not essential, the locating slats 120 are for helping to align the first carrier component 101 with the second carrier component 102, and for helping to align the aerosol generating component 103 relative to the first and second carrier components 101, 102 when assembled.

The second carrier component 102 is arranged onto the aerosol generating component 103 and the first carrier component 101 to sandwich the aerosol generating component 103 between the second carrier component 102 and the first carrier component 101. This may be achieved in various ways. For example, and with reference to Figs. 9A-C, the second carrier component 102 may be lowered onto the first carrier component 101, such that respective opposing edges 107, 108 of the second carrier component 102 contact the respective ramp portions 1110, 1120 (as shown schematically in Fig. 9B). Following this, the first carrier component 101 and the second carrier component 102 may be pressed together, such that the respective opposing edges 107, 108 of the second carrier component 102 slide down the respective ramp portions 1110, 1120. This causes the projections 111A, 112A to progressively flex apart (as shown schematically in Fig. 9B). Once the edges 107, 108 of the second carrier component 102 are pressed beyond the ends of the respective ramp portions 1110, 1120 such that the edges 107, 108 are lower than the respective ramp portions 111C, 112C, the projections 111A, 112A resiliently flex inwardly, whereupon the retaining portions 111B, 112B latch over the edges 107, 108.

Accordingly, the first and second carrier components 101, 102 and the aerosol generating component 103 are securely connected together. In this configuration, the distance between the second carrier component 102 and the first carrier component 101 (denoted by "d" in Figs. 6-8) can be accurately and consistently maintained, even when the atomiser 100 is subjected to sudden movement and/or impact. In this way, the size of the gap through which aerosolisable material is fed to the aerosol generating component 103 can be accurately and consistently maintained. This improves the reliability of the atomiser 100. Moreover, connecting the carrier components 101, 102 together as outlined herein (e.g. using one or more of a snap fit, press fit, and an interference fit; and of via the resiliently flexible projections 111A, 111A) can facilitate efficient manufacture of the atomiser 100. That is, the first and second carrier components 101, 102 and the aerosol generating component 103 may be assembled simply by pushing the carrier components 101, 102 together with the aerosol generating component 103 between the carrier components 101, 102. In this way, further manufacturing steps for assembling the carrier components 101, 102 and the aerosol generating component 103, which complicate the manufacturing process, may be avoided.

In some embodiments, the or each engaging element 111, 112 may be configured to grip the other of the first carrier component 101 and the second carrier component 102. This may further secure the connection between the first and second carrier components 101, 102.

In some embodiments, the atomiser 100 may comprise alignment means for aligning the aerosol generating component between the first carrier component 101 and the second carrier component 102. The alignment means may be such that the distance between the first carrier component 101 and the aerosol generating component 103 is substantially the same as the distance between the second carrier component 102 and the aerosol generating component 103. In this way, substantially equal capillary forces at both sides of the aerosol generating component 103 can be achieved.

The alignment means may be in the form of one or more projections (e.g. one or more lugs). The alignment means may be provided on one or each of the first carrier component 101 and the second carrier component 102. The alignment mean may be provided on respective sides of the aerosol generating component 103. The alignment means may be configured to engage with respective ends of the aerosol generating component 103. The alignment means may be configured to engage with respective parts of the aerosol generating component 103 towards respective ends of the aerosol generating component 103.

As described above, Figs. 2 and 10 also show an end cap 200. As shown in those Figs., the end cap 200 is fitted to the upstream portion 104 of the first carrier component 101. In particular, the upstream portion 104 of the first carrier component 101 may be slidably received into the sleeve 201 of the end cap 200. The end cap 200 may be provided with various ports, which can be used to fill the reservoir of the article of the system 10 (when assembled) with aerosolisable material.

The skilled person will appreciate that the atomiser 100 can be manufactured in various different ways, and that the embodiments described herein serve as a representative example.

For example, the manner in which the aerosol generating component 103 is arranged between the second carrier component 102 and the first carrier component 101 may be varied.

Thus, in the embodiment of Fig. 2, the atomiser 100, once assembled, is of a generally rectangular prismatic form with a central passageway forming an aerosol generating chamber defined by the respective recesses 119 with the lower and carrier components 101, 102, providing an airflow path through the atomiser 100 that will connect to an air inlet and an air outlet in a complete electronic cigarette 10. It will be appreciated that, in use, the atomiser 100 of Fig. 2 may be surrounded on either side by the reservoir for aerosolisable material. As discussed, the distance "d" between the first and second carrier components 101, 102 corresponds to a gap that is in fluid communication with the reservoir. The gap provides a capillary channel (one each side) which extends along both sides of the aerosol generating component 103 and through which it enters the pores of the aerosol generating component 103 for vaporisation to generate a vapour in the aerosol generating chamber during use. The passing air collects the vapour to generate an aerosol to be drawn out of the aerosol generating chamber and along a further part of the airflow path through the electronic cigarette 10 to exit the air outlet as a user inhales on the electronic cigarette 10.

When installed in an electronic cigarette 10, an article comprising the atomiser 100 may be arranged such that the longitudinal direction of the aerosol generating component 103, corresponding to the direction of airflow through the atomiser from the upstream end to the downstream end, is aligned parallel to the longitudinal axis of the electronic cigarette 10 for an end-to-end system such as the Fig. 1 example, or at least parallel to the longitudinal axis of the device in a side-by-side system having the device arranged to the side of the article. This is not compulsory, however, and in the current description, the term "longitudinal" is intended to refer to the dimensions and orientation of the atomiser, in particular the dimension of the aerosol generating component along the airflow path from an atomiser inlet at the upstream end of the atomiser, and through the vaporisation chamber to the atomiser outlet at the downstream end of the atomiser.

A further embodiment of an atomiser 100 according to the present disclosure is illustrated in Figs. 11A-E. This embodiment is similar to the embodiment of Figs. 2-5, and so only the certain features are described below. The atomiser 100 comprises a first carrier component 101, a second carrier component 102, and an aerosol generating component 103. The first and second carrier components 101, 102 are separated to provide the gap G (see Fig. 11A) through which aerosolisable material can be fed to the aerosol generating component 103 in use (e.g. from a reservoir, which is not shown). The gap G provides a capillary channel (one each side) which extends along both sides of the aerosol generating component 103. In this particular embodiment, the aerosol generating component 103 is a substantially planar heating element 103.

The first and second carrier components 101, 102 may be provided in various forms and dimensions. When the two carrier components 101, 102 are brought together to sandwich the aerosol generating component 103 therebetween, the carrier components 101, 102 form a carrier assembly with an airflow path 110 running down the interior thereof and in which the aerosol generating component 103 is at least partially disposed. The airflow path 110 comprises an aerosol generation chamber. The carrier assembly may take on an elongate form, or may have width and length dimensions that are similar. The form and dimensions of the airflow path 110 may be varied.

In this embodiment, the first carrier component 101 and the second carrier component 102 are connected together by a snap fit. In particular, the first carrier component 101 comprises a pair of projections 111 provided towards its downstream portion 105, which projections 111 being configured to engage via a snap-fit with a corresponding ledge 121 of the second carrier component 102; and the second carrier component 102 comprises a projection 112 provided at its upstream portion 107, which projection 112 being configured to engage via a snap-fit with a corresponding ledge 123 of the first carrier component 101. It will be understood that the nature of the connection between the first carrier component 101 and the second carrier component 102 may be varied.

Finally, it will be appreciated that the atomiser disclosed herein can be located within an article for use as part of a non-combustible aerosol provision system. Said article, as described herein, would typically comprise a housing, a reservoir for aerosolisable material, and a mouthpiece. The atomiser may be provided within the housing. Thus, the present disclosure also contemplates an article comprising the atomiser disclosed herein.

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

Claims 1. 2. 4. 7.An atomiser for use in a non-combustible aerosol provision system, the atomiser comprising: a first carrier component; a second carrier component; and a substantially planar aerosol generating component arranged between the first carrier component and the second carrier component; wherein the first carrier component and the second carrier component are connected together.
An atomiser as claimed in claim 1, wherein the first carrier component and the second carrier component are connected together by one or more of: a snap fit, a press fit, and an interference fit.
An atomiser as claimed in claim 1 or 2, wherein one of the first carrier component and the second carrier component comprises at least one engaging element configured to engage with the other of the first carrier component and the second carrier component.
An atomiser as claimed in claim 3, wherein one of the first carrier component and the second carrier component comprises a plurality of engaging elements configured to engage with the other of the first carrier component and the second carrier component.
An atomiser as claimed in claim 4, wherein the engaging elements are configured to engage with opposing sections of the other of the first carrier component and the second carrier component.
An atomiser as claimed in claim 5, wherein the engaging elements comprise at least one pair of engaging elements, each pair being configured to engage with opposing sections of the other of the first carrier component and the second carrier component.
An atomiser as claimed in any one of claims 4-6, wherein the engaging elements are arranged in the same plane as each other.
8. An atomiser as claimed in claim 7, wherein the plane in which the engaging elements are arranged is substantially parallel to the substantially planar aerosol generating component.
9. An atomiser as claimed in any one of claims 1-8, wherein the or each engaging element comprises a projection.
10. An atomiser as claimed in claim 9, wherein the projection is resiliently flexible.
11. An atomiser as claimed in any one of claims 1-10, wherein the or each engaging element comprises a retaining portion for retaining the other of the first carrier component and the second carrier component.
12. An atomiser as claimed in claim 11, wherein the retaining portion latches over at least part of the other of the first carrier component and the second carrier component
13. An atomiser as claimed in any one of claims 1-12, wherein the or each engaging element comprises a ramp portion.
14. An atomiser as claimed in any one of claims 1-13, wherein the or each engaging element is configured to resiliently retain the other of the first carrier component and the second carrier component.
15. An atomiser as claimed in any one of claims 1-14, wherein the first carrier component and the second carrier component are connected together to retain the substantially planar aerosol generating component.
16. An atomiser as claimed in any one of claims 1-15, wherein the first carrier component and the second carrier component are connected together to bias the substantially planar aerosol generating component against one or more electrical contacts of the atomiser.
17. An atomiser as claimed in any one of claims 1-16, wherein the first carrier component and the second carrier component are connected together by one or more of a snap fit, a press fit, and an interference fit to bias the substantially planar aerosol generating component against one or more electrical contacts of the atomiser
18. An atomiser as claimed in any one of claims 1-17, wherein the first carrier component and the second carrier component together provide an airflow path.
19. An atomiser as claimed in claim 18, wherein the airflow path is provided between the first carrier component and the second carrier component.
20. An atomiser as claimed in claim 18 or 19, wherein the airflow path is substantially parallel to the plane of the substantially planar aerosol generating component
21. An atomiser as claimed in any one of claims 1-20, wherein the first carrier component is of a generally planar form and the second carrier component is of a generally planar form, and wherein the first carrier component, the second carrier component, and the substantially planar aerosol generating component are aligned in substantially parallel planes.
22. An atomiser as claimed in any one of claims 1-21, wherein the aerosol generating component is formed from a porous material.
23. An atomiser as claimed in any one of claims 1-22, wherein the aerosol generating component is formed from a woven or weave structure, mesh structure, fabric structure, open-pored fiber structure, open-pored sintered structure, open-pored foam or open-pored deposition structure.
24. An article for use as part of a non-combustible aerosol provision system, the article comprising an atomiser as claimed in any one of claims 1-23.
25. A non-combustible aerosol provision system comprising: an article comprising an atomiser as claimed in any one of claims 1-23; and a device comprising one or more of a power source and a controller.
26. A method of manufacturing an atomiser, the method comprising: providing a first carrier component, a second carrier component, and a substantially planar aerosol generating component; arranging the substantially planar aerosol generating component between the first carrier component and the second carrier component; and connecting together the first carrier component and the second carrier component.