WO2024200664A1

WO2024200664A1 - Aerosol generator

Info

Publication number: WO2024200664A1
Application number: PCT/EP2024/058499
Authority: WO
Inventors: Tom Woodman; Mark Potter
Original assignee: Nicoventures Trading Limited
Priority date: 2023-03-29
Filing date: 2024-03-28
Publication date: 2024-10-03

Abstract

An aerosol generator of an article for an aerosol provision device is provided. The aerosol generator comprises aerosol generating material; and a resistive heating layer (40) comprising a resistive heating element (42). The resistive heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol. The resistive heating element is at least a portion of an electrically conductive path between an electrical contact of a first type (44) and an electrical contact of a second type (46). The resistive heating layer comprises a plurality of surface features (43a, 43b, 43c)

Description

Aerosol Generator

Technical Field

The present specification relates to an aerosol generator of an article for an aerosol provision device. The present specification also relates to an electrically resistive heating device, such as an aerosol generator or a consumable part of an aerosol generating device, an article for an aerosol provision device, an aerosol provision system, and a method of forming an aerosol generator of an article for an aerosol provision device.

Background

Aerosol generators for use in aerosol generating devices, such as an e-cigarettes, have been developed for releasing compounds without requiring combustion. Some example aerosol generating devices including resistive heater for use in generating an aerosol. There remains a need for further developments in such devices.

Summary

The scope of protection sought for various embodiments of the invention is set out by the independent claims. The embodiments and features, if any, described in this specification that do not fall under the scope of the independent claims are to be interpreted as examples useful for understanding various embodiments of the invention.

According to an aspect, there is provided an aerosol generator of an article for an aerosol provision device, the aerosol generator comprising: aerosol generating material; and a resistive heating layer comprising a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; wherein the resistive heating element is at least a portion of an electrically conductive path between an electrical contact of a first type and an electrical contact of a second type; and wherein the resistive heating layer comprises a plurality of surface features.

In an embodiment of any of the above, wherein the aerosol generating material is on the resistive heating layer. In an embodiment of any of the above, wherein the plurality of surface features comprises a plurality of perforations.

In an embodiment of any of the above, wherein the plurality of surface features comprises at least one of a plurality of indents and a plurality of protrusions.

In an embodiment of any of the above, wherein at least some of the surface features are formed along the electrically conductive path. In an embodiment of any of the above, wherein the plurality of surface features are configured to at least partially determine the electrical resistance along the electrically conductive path.

In an embodiment of any of the above, comprising an array of the surface features.

In an embodiment of any of the above, wherein the surface features are regularly spaced in the array of surface features.

In an embodiment of any of the above, the aerosol generator comprises an aerosol generating layer including the aerosol generating material.

In an embodiment of any of the above, wherein the aerosol generating layer comprises a plurality of aerosol generating layer perforations. In an embodiment of any of the above, wherein the plurality of surface features of the resistive heating layer are aligned with the plurality of aerosol generating layer perforations.

In an embodiment of any of the above, wherein the aerosol generating layer is free from perforations.

In an embodiment of any of the above, comprising a support configured to support the resistive heating layer. In an embodiment of any of the above, wherein the support comprises a support layer. In an embodiment of any of the above, the support is electrically insulative.

In an embodiment of any of the above, the support comprises at least one of paper and card.

In an embodiment of any of the above, the aerosol generating material is in direct contact with the resistive heating layer. In an embodiment of any of the above, the aerosol generating layer is in direct contact with the resistive heating layer.

In an embodiment of any of the above, the aerosol generating material is in indirect contact with the resistive heating layer. In an embodiment of any of the above, the aerosol generating layer is in indirect contact with the resistive heating layer. In an embodiment of any of the above, the resistive heating layer and the support layer define a substrate.

In an embodiment of any of the above, the aerosol generator comprises a laminate comprising the resistive heating layer and the support layer.

In an embodiment of any of the above, the laminate comprises the aerosol generating layer.

In an embodiment of any of the above, the support layer comprises a card layer.

In an embodiment of any of the above, wherein the support is free from perforations.

In an embodiment of any of the above, wherein the support comprises a plurality of support perforations. In an embodiment of any of the above, wherein the plurality of surface features of the resistive heating layer are aligned with the plurality of support perforations.

In an embodiment of any of the above, wherein the aerosol generating material forms a physical bond with the support. In an embodiment of any of the above, wherein the resistive heating layer is sandwiched between the support and the aerosol generating material. In an embodiment of any of the above, wherein the resistive heating layer is sandwiched between the support and the aerosol generating layer.

In an embodiment of any of the above, an exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and the width, wherein the length is greater than or equal to the width, and wherein the width is greater than the depth.

In an embodiment of any of the above, the aerosol generating layer is a continuous aerosol generating layer.

In an embodiment of any of the above, the aerosol generating layer is a discontinuous aerosol generating layer.

In an embodiment of any of the above, the aerosol generating layer comprises a plurality of discrete aerosol generating portions. In an embodiment of any of the above, the resistive heating layer forms the electrical contact of the first type.

In an embodiment of any of the above, the resistive heating layer forms the electrical contact of the second type.

In an embodiment of any of the above, wherein the aerosol generator comprises an electrical track of a first type extending from the heating element and comprising the electrical contact of the first type. In an embodiment of any of the above, wherein the electrical contact of the first type is configured to electrically connect with a device electrical connector.

In an embodiment of any of the above, wherein the aerosol generator comprises an electrical track of a second type extending from the heating element and comprising the electrical contact of the second type. In an embodiment of any of the above, wherein the electrical contact of the second type is configured to electrically connect with a device electrical connector. In an embodiment of any of the above, the resistive heating element is one of a plurality of resistive heating elements.

In an embodiment of any of the above, the resistive heating layer comprises the plurality of heating elements, wherein each resistive heating element is at least a portion of an electrically conductive path between the electrical contact of a first type and the electrical contact of a second type.

In an embodiment of any of the above, wherein each resistive heating element comprises a plurality of surface features.

In an embodiment of any of the above, wherein each resistive heating element has the same electrical resistance.

In an embodiment of any of the above, wherein at least one resistive heating element has a different electrical resistance to another one of the resistive heating elements.

In an embodiment of any of the above, wherein each resistive heating element has the same plurality of surface features.

In an embodiment of any of the above, wherein at least one resistive heating element has a different plurality of surface features to another one of the resistive heating elements.

In an embodiment of any of the above, wherein the plurality of surface features of at least one resistive heating element has a different at least one of size, quantity and distribution of surface features to another one of the resistive heating elements.

In an embodiment of any of the above, wherein the electrical contact of a first type and the electrical contact of a second type enable the electric current to be individually provided to each of the plurality of heating elements. In an embodiment of any of the above, one of the discrete aerosol generating portions is associated with a corresponding one of the plurality of resistive heating elements.

In an embodiment of any of the above, the aerosol generating layer comprises at least one of dots, strips and patches.

In an embodiment of any of the above, wherein the resistive heating element is a first heating element and the resistive heating layer forms a second resistive heating element, each resistive heating element providing an electrically conductive path for resistive heating of a portion of the aerosol generating material to generate an aerosol at the respective portion of the aerosol generating material.

In an embodiment of any of the above, wherein the resistive heating layer forms an array of resistive heating elements comprising at least the first resistive heating element and the second resistive heating element.

In an embodiment of any of the above, wherein each of the first type of electrical contact and the second type of electrical contact are configured to enable an electric current to be individually provided to each of the resistive heating elements. In an embodiment of any of the above, wherein the aerosol generating layer comprises a film or gel layer comprising the aerosol generating material.

In an embodiment of any of the above, the aerosol generator comprises a plurality of the first type of electrical contact, wherein each of the heating elements comprises a separate first type of electrical contact.

In an embodiment of any of the above, the aerosol generator comprises a plurality of the second type of electrical contacts, wherein each of the resistive heating elements comprises a separate second type of electrical contact.

In an embodiment of any of the above, wherein the aerosol generator comprises a single second type of electrical contact.

In an embodiment of any of the above, wherein the single second type of electrical contact is shared between each of the resistive heating elements. In an embodiment of any of the above, wherein the resistive heating element is formed by at least one of: cutting the resistive heating layer; chemically etching the resistive heating layer; forming or pressing the resistive heating layer in the substrate; and printing the resistive heating layer.

In an embodiment of any of the above, wherein the resistive heating layer is in the form of a foil. According to an aspect, there is provided an aerosol generator comprising: an aerosolisable layer incorporating an aerosolisable material; and an electrically conductive layer in contact with said aerosolisable layer, wherein said electrically conductive layer comprises a plurality of perforations and wherein said electrically conductive layer comprises one or more heating elements, the or each heating element providing an electrically conductive path for resistive heating of a portion of said aerosolisable material to generate an aerosol, wherein the or each heating element extends from an electrical connection of a first type to an electrical connection of a second type. The aerosolisable layer may comprise a film or a gel incorporating said aerosolisable material.

In an embodiment of any of the above, the electrically conductive layer is formed into said one or more heating elements. In an embodiment of any of the above, said electrically conductive layer may be formed into a plurality of heating elements, each heating element providing an electrically conductive path for resistive heating of a portion of said aerosolisable material to generate a vapour at the respective portion of the support.

In an embodiment of any of the above, the electrical connections may enable the electric current to be individually provided to each of the plurality of heating elements (e.g. a plurality of positive electrical connections). In an embodiment of any of the above, each of said heating elements may have a separate electrical connection of the first type. In an embodiment of any of the above, wherein the aerosol generator comprises a plurality of electrical connections of the second type (e.g. negative electrical connections). In an embodiment of any of the above, wherein the aerosol generator comprises a single connection of a second type (e.g. a single negative electrical connection).

In an embodiment of any of the above, wherein separate connections of the first and second type are provided for each heating zone instead of using a common connection of the second type. In an embodiment of any of the above, wherein , electrical connections of the first type are arranged on a first edge of the electrically conductive layer and electrical connections of the second type are arranged on a second edge of the electrically conductive layer. In an embodiment of any of the above, wherein electrical connections of the first and second type may be provided on opposite sides of an area in which the heating elements are provided. In an embodiment of any of the above, wherein some or all of the electrical connections of the first and second type are provided on the same edge of the electrically conductive layer or the second side of the area in which the heating elements are provided.

In an embodiment of any of the above, wherein the heating elements may be formed by cutting said electrically conductive layer (e.g. using a laser cutter).

In an embodiment of any of the above, the heating elements may be formed by one or more of: chemically etching said electrically conductive layer; forming or pressing the electrically conductive layer in a/the substrate; and printing said electrically conductive layer.

In an embodiment of any of the above, wherein each heating element comprises a nonstraight electrically conducting path (e.g. a meandering or serpentine path) between the first and second electrical connections. In an embodiment of any of the above, wherein said aerosolisable material comprises a plurality of perforations. In an embodiment of any of the above, wherein each heating element is a linear heating element comprising a conducting path extending across a length of the aerosolisable layer. In an embodiment of any of the above, wherein the electrically conductive layer may be in the form of a foil. In an embodiment of any of the above, wherein the electrically conductive layer may be a metal layer (e.g. a metal foil, such as an aluminium foil).

According to an aspect, there is provided an article may comprise an aerosol generator in accordance with an embodiment of any of the above embodiments. In an embodiment of any of the above, wherein the article is a consumable of an aerosol generating system.

According to an aspect, there is provided an aerosol provision device configured to receive an aerosol generator in accordance with an embodiment of any of the above.

According to an aspect, there is provided an aerosol provision system comprising: an aerosol generator in accordance with an embodiment of any of the above; and an aerosol provision device configured to receive the aerosol generator or the article.

According to an aspect, there is provided a blank for forming an aerosol generator of an article for an aerosol provision device comprising: a resistive heating layer, wherein the resistive heating layer forms a heating element, the heating element providing an electrically conductive path for resistive heating; an electrical contact of a first type; and an electrical contact of a second type; wherein the heating element extends between the electrical contact of the first type and the electrical contact of the second type, and wherein the resistive heating layer comprises a plurality of surface features.

In an embodiment of any of the above, wherein the plurality of surface features comprises a plurality of perforations.

According to an aspect, there is provided a method comprising: forming a resistive heating layer comprising a resistive heating element; forming an aerosol generating layer including aerosol generating material on the resistive heating layer; wherein the resistive heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol; wherein the resistive heating element is at least a portion of an electrically conductive path between an electrical contact of a first type and an electrical contact of a second type; and forming a plurality of surface features on the resistive heating layer.

According to an aspect, there is provided a method comprising: forming a resistive heating layer comprising a resistive heating element; disposing aerosol generating material on the resistive heating layer; wherein the resistive heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol; wherein the resistive heating element is at least a portion of an electrically conductive path between an electrical contact of a first type and an electrical contact of a second type; and forming a plurality of surface features on the resistive heating layer.

According to an aspect, there is provided a method comprising: forming an electrically conductive layer into a one or more heating elements, the or each heating element providing an electrically conductive path for resistive heating of a portion of an aerosolisable material to generate an aerosol; and placing the formed electrically conductive layer in contact with an aerosolisable layer, wherein said aerosolisable layer incorporates said aerosolisable material. The or each heating element extends from an electrical connection of a first type to an electrical connection of a second type. The electrically conductive layer comprises a plurality of perforations. The aerosolisable layer may comprise a film or a gel incorporating said aerosolisable material.

In an embodiment of any of the above, wherein forming said electrically conductive layer may comprise forming said perforations. In an embodiment of any of the above, the method comprising forming said perforations in said electrically conductive layer before placing the formed electrically conductive later in contact with said aerosolisable layer. In an embodiment of any of the above, the method comprising forming said perforations in said electrically conductive layer after placing the formed electrically conductive layer in contact with said aerosolisable layer. In an embodiment of any of the above, the method comprising forming perforations in said aerosolisable material. In an embodiment of any of the above, wherein said electrically conductive layer is formed into a plurality of heating elements, each heating element providing an electrically conductive path for resistive heating of a portion of said aerosolisable material to generate an aerosol at the respective portion of the aerosolisable layer. In an embodiment of any of the above, the electrical connections may enable the electric current to be individually provided to each of the plurality of heating elements.

In an embodiment of any of the above, the method comprising forming said heating elements, at least in part, by cutting said electrically conductive layer (e.g. using a laser cutter). In an embodiment of any of the above, the method comprising forming said heating elements, at least in part, by chemically etching said electrically conductive layer. In an embodiment of any of the above, the method comprising forming said heating elements, at last in part, by printing said electrically conductive layer.

In an embodiment of any of the above, wherein each heating element comprises a non-straight electrically conducting path (e.g. a meandering or serpentine path) between the first and second electrical connections.

According to an aspect, there is provided an article comprising an aerosol generator as set out in any of the above or formed in accordance with the method of any of the above). The article may be a consumable of an aerosol generating system.

According to an aspect, there is provided a non-combustible aerosol generating device configured to receive an aerosol generator, article or consumable as set out in any of the above or formed in accordance with the method of any of the above. According to an aspect, there is provided a system comprising: a non-combustible aerosol generating device of any of the above and an aerosol generator, article or consumable as set out in any of the above or formed in accordance with the method of any of the above. The aerosol generator, article or consumable may further comprise an apparatus as set out in any of the above.

According to an aspect, there is provided a kit of parts comprising: a non-combustible aerosol generating device of the fourth aspect and an aerosol generator, article or consumable as set out in any of the above or formed in accordance with the method of any of the above , wherein said aerosol generator is detachable from said non- combustible aerosol generating device. The kit of parts may further comprise an apparatus as set out in any of the above. The non-combustible aerosol generating device may comprise an integrated battery.

Brief Description of the Drawings Example embodiments will now be described, by way of example only, with reference to the following schematic drawings, in which:

FIG. 1 is a block diagram of an aerosol provision system;

FIG. 2 is a block diagram of an aerosol generator; FIG. 3 is a block diagram of an aerosol generator; FIG. 4 shows an electrically conductive layer;

FIG. 5 shows an electrically conductive layer;

FIG. 6 shows a heating element;

FIG. 7 shows an electrically conductive layer; FIG. 8 shows an electrically conductive layer;

FIG. 9 shows an electrically conductive layer;

FIGS. 10 to 13 are flow charts showing algorithms;

FIG. 14 shows an aerosol generator being formed;

FIG. 15 shows an electrically conductive layer being formed; FIGS. 16 to 18 are flow charts showing algorithms;

FIG. 19 shows an electrically conductive layer;

FIG. 20 shows an electrically conductive layer;

FIG. 21 shows part of an aerosol generator;

FIG. 22 shows a connector used in some embodiments; and FIG. 23 is a block diagram of an aerosol generating system.

Detailed Description

As used herein, the term “delivery mechanism” is intended to encompass systems that deliver a substance to a user, and includes: non-combustible aerosol provision systems that release compounds from an aerosolisable material without combusting the aerosolisable material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosolisable materials; and articles comprising aerosolisable material and configured to be used in one of these non-combustible aerosol provision systems.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system. In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol- generating material and a solid aerosol-generating material. The solid aerosolgenerating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source. In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent. In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

In some embodiments, the substance to be delivered may be an aerosol-generating material or a material that is not intended to be aerosolised. As appropriate, either 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.

In some embodiments, the substance to be delivered comprises an active substance (sometimes referred to herein as an active compound).

The active substance as used herein may be 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, or digiceutical or other technical/electronic devices that may induce a physiological response, such as vagus nerve stimulation (VGS). 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. In one embodiment, the active substance is a legally permissible recreational drug.

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise one or more constituents, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes. As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, Wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from rooibos and fennel. In some embodiments, the substance to be delivered comprises a flavour.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, Wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang- ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco. In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

Aerosolisable material, which also may be referred to herein as aerosol generating material, is material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosolisable material may, for example, be in the form of a solid, liquid or gel which may or may not contain nicotine and/or flavourants.

Aerosol-generating material (which is sometimes referred to herein as an aerosolisable material) is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/or flavourants.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free. The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. The aerosol-generating film may be substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free.

The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm.

For example, the thickness may be in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm.

The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The aerosol-generating film may be discontinuous. For example, the aerosolgenerating film may comprise one or more discrete portions or regions of aerosolgenerating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosolgenerating film.

The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

The aerosol-generating material may be an “amorphous solid”. In some embodiments, the amorphous solid is a “monolithic solid”. The aerosol-generating material may be non-fibrous or fibrous. In some embodiments, the aerosol-generating material may be a dried gel. The aerosol-generating material may be a solid material that may retain some fluid, such as liquid, within it. In some embodiments the retained fluid may be water (such as water absorbed from the surroundings of the aerosol-generating material) or the retained fluid may be solvent (such as when the aerosol-generating material is formed from a slurry). In some embodiments, the solvent may be water.

The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, 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. The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosolmodifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor. An aerosol provision device can receive an article comprising aerosol generating material for heating. An “article” in this context is a component that includes or contains in use the aerosol generating material, which is heated to volatilise the aerosol generating material, and optionally other components in use. A user may insert the article into or onto the aerosol provision device before it is heated to produce an aerosol, which the user subsequently inhales.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

FIG. 1 is a block diagram of an aerosol generating device, indicated generally by the reference numeral 10, in accordance with an example embodiment.

The aerosol generating device 10 comprises a battery 11 (e.g. a rechargeable battery), a control circuit 12, and an aerosol generator 13. As discussed in detail below, the aerosol generator 13 comprises a resistive heater for heating an aerosolisable material (e.g. a film or a gel) to generate an aerosol (e.g. a vapour). The aerosolisable material is sometimes referred to an as aerosol generating material.

The aerosol generating device 10 forms an aerosol provision system comprising an aerosol provision device and an article comprising the aerosol generator 13. The resistive heater comprises at least one resistive heating element.

The battery 11 acts a power source. The control circuit acts as a controller, and comprises a processor and a memory. The control circuit is configured to implement the or each method set out below. In the use of the device 10, air is drawn into an air inlet of the aerosol generator 13, as indicated by arrow 16. An aerosol generated by the aerosol generator 13 exits the device at an air outlet, as indicated by arrow 17 (for example into the mouth of a user of the device 10).

In some example embodiments, the aerosol generating device 10 comprises two main components, namely a control section 2 (which may be referred to as a reusable part) and a consumable part 4 (which may be referred to as a replaceable or disposable cartridge). In the use of the aerosol generating device 10, the control section 2 and the consumable part 4 may be releasably connected at an interface 6. The consumable part 4 may be removable and replaceable (e.g. when the consumable part is used), with the control section 2 being re-used with a different consumable part.

The aerosol generating device 10, also referred to as the aerosol provision system, comprises the control section 2, which may also be referred to as the aerosol provision device 10, and the consumable part 4, which may also be referred to as the article 4.

The aerosol generator 13 forms part of the article 4. The aerosol generator 13 comprises a resistive heating arrangement configured to heat aerosol generating material, for example at least one of a film or and a gel to generate an aerosol.

The or each heating element in embodiments is a resistive heating element, as described in detail below. In such arrangements the system comprises a resistive heating generator including components to heat the heating arrangement via a resistive heating process. In this case, an electrical current is directly applied to a resistive heating element, and the resulting flow of current in the heating element, acting as a heating component, causes the heating element to be heated by Joule heating. The resistive heating element comprises resistive material configured to generate heat when a suitable electrical current passes through it, and the heating arrangement comprises electrical contacts for supplying electrical current to the resistive material.

The provision of a resistive heating arrangement allows for a compact arrangement. Resistive heating provides an efficient configuration.

A ‘section’ may be referred to as a ‘part’. A ‘part’ may be referred to as a ‘section’. A consumable part may be referred to as a replaceable or disposable article. Of course, the aerosol generating device 10 is provided by way of example only and is highly schematic. Many alternative aerosol generating devices and other devices may be used in example implementations of the principles described here. For example, in some example embodiments, air is drawn into an air inlet in the control section 2, passes through the interface 6, and exits the consumable part 4.

The aerosol generator 13 is configured to generate an aerosol from the aerosol generating material, also known as aerosolisable material, upon operation of the aerosol provision system, as will be described in detail below. The aerosol provision system 10 is elongate, extending along a longitudinal axis. The aerosol provision system 10 has a proximal end, which will be closest to the user (e.g. the user’s mouth) when in use by the user to inhale the aerosol generated by the aerosol provision system, and a distal end which will be furthest from the user when in use. The proximal end may also be referred to as the “mouth end”. The aerosol provision system accordingly defines a proximal direction, which is directed towards the user when in use. Further, the aerosol provision system 10 likewise defines a distal direction, which is directed away from the user when in use. The terms ‘proximal’ and ‘distal’ as applied to features of the system 10 will be described by reference to the relative positioning of such features with respect to each other in a proximal-distal direction along a longitudinal axis.

In embodiments, the aerosol generator 13 may be fully or partially inserted into the aerosol provision device 10. The configuration of the aerosol provision device 10 may vary, for example an opening may be in a longitudinal side wall of the aerosol provision device 10, and/or may be closed by another feature of the aerosol provision device 10 during use. In the present configuration, the article 4 defines a mouthpiece at the proximal end. In embodiments, the aerosol provision device 10 defines the mouthpiece. The user places their mouth over the mouthpiece during use.

FIG. 2 is a block diagram of an aerosol generator, indicated generally by the reference numeral 20, in accordance with an example embodiment. The aerosol generator 20 is an example implementation of the aerosol generator 13 of the aerosol generating device 10 described above. The aerosol generator 20 comprises an aerosolisable layer 22 (incorporating an aerosolisable material) and an electrically conductive layer 24 in contact with said aerosolisable layer. As described in detail below, the electrically conductive layer 24 is formed into one or more heating elements, each heating element providing an electrically conductive path for resistive heating of a portion of the aerosolisable material of the aerosolisable layer 22 to generate an aerosol. The aerosolisable material may, for example, be in the form of a film or a gel.

The aerosolisable layer 22, also referred to as an aerosol generating layer 22, comprises the aerosolisable material, also known as aerosol generating material.

The electrically conductive layer 24 is formed as a resistive heating layer. The resistive heating layer comprises material capable of being resistively heated in response to an electrical current being passed through the material.

The aerosol generator 20 comprises the resistive heating layer 24. The aerosol generating layer 22 is on the resistive heating layer 24. The aerosol generating layer 22 is in direct contact with the resistive heating layer 24. In embodiments, the aerosol generating layer 22 is in indirect contact with the resistive heating layer 24. The resistive heating layer 24 may in embodiments comprise a coating. The coating of the resistive heating layer 24 may be on the electrically conductive material.

The electrically conductive layer 24 may take the form of a metal layer, such as an aluminium layer, or a non-metallic material (such as graphene). The electrically conductive layer may be in the form of a foil (e.g. an aluminium foil).

The aerosol generator 20 is configured to generate an aerosol from the aerosol generating material upon operation of the aerosol provision system 10, as will be described in detail below.

FIG. 3 is a block diagram of an aerosol generator, indicating generally by the reference numeral 30, in accordance with an example embodiment. The aerosol generator 30 is an example implementation of the aerosol generator 13 described above. The aerosol generator 30 comprises the aerosolisable layer 22 and the electrically conductive layer 24 described above. The aerosol generator 30 further comprises a support (or substrate) 32. The support 32 may comprise a paper or card material that provides structural support for the aerosol generator 30. As shown in FIG. 3, in the aerosol generator 30, the electrically conductive layer 24 is sandwiched between the support 32 and the aerosolisable layer 22.

In embodiments described herein, the support 32 may be configured as a support layer. The support 32 may electrically insulative. The support 32 may comprise at least one of paper and card. In embodiments, the aerosolisable layer 22 is in direct contact with the electrically conductive layer 24. The aerosolisable layer 22 may be in indirect contact with the electrically conductive layer 24. The electrically conductive layer 24 and the support layer defines a substrate. The substrate 32 supports the aerosol generating layer 22. The support layer comprises a card layer. The support 32 is free from perforations.

In embodiments, the aerosol generator 30 may comprise a laminate comprising the electrically conductive layer 24 and the support layer 32. In embodiments, the laminate comprises the aerosolisable layer 22. The aerosolisable layer 22 may be formed as a contiguous configuration, or may be formed from discrete portions. The discrete portions may comprise one or more of dots, strips, spirals, or other shapes. In embodiments, the discrete portions align with the heating elements.

One or more of the aerosolisable layer 22, electrically conductive layer 24 and the support layer 32 may comprise a further layer. For example, the support layer 32 may comprise a backing layer or an intermediate layer. The support layer 32 in embodiments is omitted.

The or each aerosol generator 30 are formed in a stacked configuration. In embodiments, other arrangements such as a tubular arrangement of the article are envisaged. In such tubular arrangements the aerosol generator 30 defines a tubular configuration. Tubular may include circular cross-sectional and other polygonal shapes.

In embodiments, as shown in the Figures, the article 30 has a flat configuration. That is, wherein an exterior of the article has a length, a width perpendicular to the length, and a depth perpendicular to each of the length and the width, wherein the length is greater than or equal to the width, and wherein the width is greater than the depth. Other configurations are envisaged. FIG. 4 shows an electrically conductive layer, indicated generally by the reference numeral 40, in accordance with an example embodiment. The electrically conductive layer 40 comprises a heating element 42, a first electrical connection 44 and a second electrical connection 46. In some example embodiments, the first electrical connection 44 provides a positive connection and the second electrical connection 46 provides a negative connection such that electrical current flows between the electrical connections through the heating element 42. As shown in FIG. 4, the heating element 42 comprises a plurality of perforations (including perforations 43a, 43b, 43c etc.).

The plurality of perforations act as surface features. In embodiments, the surface features comprise at least one of protrusions, recesses, indentations, depressions, holes, perforations, gaps, etc. Surface features may be a localised distortion or formation of a layer such that at least one of the volume of material across the thickness and/or width of the heating element at a particular position or positions along the heating element differs from the volume of material across the thickness and/or width of the heating element at another particular position or positions along the heating element. The embodiments described herein describe a plurality of perforations for exemplary purposes, and the skilled person would understand that the plurality of protrusions may be any surface feature. The electrical resistance of the heating element 42 may be dependent on the nature of the perforations in the conductive layer (e.g. the size, quantity and distribution of the perforations). Thus, the perforated conductive layer may have a higher electrical resistance when compared with a straight, unperforated, path between the first and second electrical connectors.

The electrically conductive layer 40 can be used as the electrically conductive layer 24 of the aerosol generator 20 or 30 (or some similar aerosol generator) such that the electrically conductive path of the heating element 42 can be used for resistive heating of a portion of an aerosolisable material to generate an aerosol. FIG. 5 shows an electrically conductive layer, indicated generally by the reference numeral 50, in accordance with an example embodiment. The electrically conductive layer 50 comprises a first heating element 52a, a second heating element 52b, first electrical connections 54a and 54b, and a second electrical connection 56. In some example embodiments, the first electrical connections 54a, 54b each provide a positive connection and the second electrical connection 56 provides a negative connection such that electrical current flows between the electrical connections through the heating elements 52s and 52b. The number of electrical connections, which may also be referred to as electrical contacts, may vary. As such, each heating element 52a, 52b extends between a discrete first type of electrical contact 54a, 54b and a common second type of electrical contact 56. As shown in FIG. 5, the heating elements 52a and 52b comprises a plurality of perforations (including perforations 53a, 53b, 53c etc.). The two heating elements are formed by a cut 58 in the electrically conductive layer that separates the first and second heating elements. The cut 58 may be generated by laser cutting or some similar process (as discussed further below).

The perforations are in the electrically conductive layer 40. In embodiments, at least some of the plurality of perforations are formed along the electrically conductive path. The plurality perforations may affect the electrical properties of the electrically conductive path. The plurality of surface features in embodiments are configured to at least partially determine the electrical resistance along the electrically conductive path.

In embodiments, the plurality of surface features in embodiments are configured to be free from or minimise an effect on the electrical resistance along the electrically conductive path. The perforations may be arranged in the heating elements in a variety of configurations. The heating elements may comprise an array of perforations. The heating elements may comprise a plurality of arrays of perforations. The perforations may be regularly spaced in the array of perforations. In various embodiments, many varieties of distributions of the perforations are envisaged. The perforations may be distributed in any one of parallel rows, parallel columns, regularly, irregularly, randomly, etc.

In embodiments, the aerosolisable layer 22 may comprise a plurality of aerosol generating layer perforations. The plurality of perforations of the electrically conductive layer are aligned with the plurality of aerosol generating layer perforations. This may be advantageous as it further enables gas flow, which will be described below. Further, quality control of manufacturing of the electrically conductive layer and the aerosoliable layer may be easier to monitor. It may also further reduce the effects of delamination, which will be described further below. In embodiments, many varieties of distributions of perforations are envisaged, including any one of parallel rows, parallel columns, regularly, irregularly, randomly etc. The aerosol generating layer may also be free from perforations. In embodiments, wherein the electrically conductive layer 24 comprises a plurality of support perforations. The support perforations are perforations that are configured to correspond to surface features of the support. The plurality of surface features of the electrically conductive layer are aligned with the plurality of support perforations. The support perforations of the electrically conductive layer 24 may help locate to electrically conductive layer on the support. In embodiments, the aerosolisable layer 22 forms a physical bond with the support 32. The electrically conductive layer is sandwiched between the support 32 and the aerosolisable layer 22.

The electrically conductive layer 50 may be used as the electrically conductive layer 24 of the aerosol generator 20 or 30 (or some similar aerosol generator) such that the electrically conductive paths of the heating elements 52a and 52b can be used for resistive heating of a portion of an aerosolisable material to generate an aerosol.

Moreover, by providing separate first electrical connections 54a and 54b, the heating elements 52a and 52b can be individually controlled in order to control the generation of aerosol from different parts of the aerosolisable material.

In embodiments, the aerosol generating layer 22 is a continuous aerosol generating layer. In embodiments, the aerosol generating layer 22 is a discontinuous aerosol generating layer. In embodiments, the aerosol generating layer comprises a plurality of discrete aerosol generating portions. Each of the heating elements may heat a corresponding discrete portion of the aerosolisable layer. Advantageously, each discrete portion can be configured to provide the user with a different experience once the aerosol is generated. FIG. 6 shows a heating element, indicated generally by the reference numeral 60, in accordance with an example embodiment. One or more heating elements 60 may be formed by the electrically conductive layer 24 described above.

The heating element 60 comprises a non-straight electrically conducting path between a first electrical connection 62 and a second electrical connector 63. In some example embodiments, the first electrical connection 62 provides a positive connection and the second electrical connection 63 provides a negative connection such that electrical current flows between the electrical connections through the path. The meandering nature of the path of the heating element 60 increases the total length of the path between the first and second electrical connectors, such that the electrical resistance of the path is increased (when compared with a straight, direct, path between the first and second electrical connectors).

In embodiments, the electrically conductive layer 24 comprises a first type of electrical track 64 extending from the heating element 62. The first type of electrical track 64 comprises the first type of electrical connection 62. The electrical contact 62 of the first type is configured to electrically connect with the device electrical connector. The first type of electrical contact 62 comprises a first type of exposed contact region. The first type of exposed contact region is exposed on the article for direct connection with the device electrical connector.

In embodiments, the electrically conductive layer 24 comprises a second type of electrical track 65 extending from the heating element 60. The second type of electrical track 65 comprises the second type of electrical connection 63. The electrical connection 63 of the second type is configured to electrically connect with the device electrical connector. The second type of electrical contact 63 comprises a second type of exposed contact region. The second type of exposed contact region is exposed on the article for direct connection with the device electrical connector. As discussed in detail below, the conducting path of the heating element 60 may be created by forming tracks in the heating element, for example by cutting the tracks into an electrically conducting layer that makes up the heating element. In some example embodiments, the tracks may have a width in the region of 0.5mm to 1mm (two example prototypes have widths of 0.93mm and 0.72mm respectively) and gaps between the tracks of less than about 0.25mm (the same two example prototypes have gaps of 0.2mm and 0.05mm respectively). The heating element may have overall dimensions of the order of 10mm x 10mm. Of course, other dimensions are possible in other example embodiments. By forming the heating element of these dimensions from an aluminium foil of having a thickness of 0.006mm and an electrical resistivity of between 2 and 6 pOhmcm, the resistance of the path has been calculated to be of the order of 1 Ohm. In one example embodiment, the resistance was measured at between 0.83 and 1.31 Ohms. The resistive heating layer comprises a plurality of resistive heating elements 40. The plurality of heating elements 40 are formed in an array as shown in Figure 5. The array of heating elements may be arranged in a single row. The array of heating elements may be arranged in a single row along a longitudinal axis of the aerosol generator. The array of heating elements may be arranged in a single row transverse a longitudinal axis of the aerosol generator. Other configurations are envisaged.

The resistive heating layer 24 comprises a first type of electrical track 44 extending from the resistive heating element 40. The first type of electrical track 44 comprises the first type of electrical contact 42. The electrical contact 42 of the first type is configured to electrically connect with the device electrical connector. The first type of electrical contact 42 comprises a first type of exposed contact region. The first type of exposed contact region is exposed on the article for direct connection with the device electrical connector. The resistive heating layer 24 comprises a second type of electrical track 45 extending from the resistive heating element 40. The second type of electrical track 45 comprises the second type of electrical contact 43. The electrical contact 43 of the second type is configured to electrically connect with the device electrical connector. The second type of electrical contact 43 comprises a second type of exposed contact region. The second type of exposed contact region is exposed on the article for direct connection with the device electrical connector.

The conducting path of the heating element in embodiments is created by defining at least one electrically insulative barrier in the resistive heating layer 24. In embodiments, the electrically insulative barrier is formed by cutting electrically conductive restrictions (i.e. electrically insulating portions), such as gaps, channels or slots into a sheet formed of electrically conductive material to form the resistive heating layer 24. In embodiments, the resistive heating layer 24 is preformed to define the or each resistive heating element 40 and then applied to the support 32. In embodiments, the resistive heating layer 24 is applied to the support 32, and the or each resistive heating element 40 then defined in the resistive heating layer 24. The or each restive heating element 40 defining the resistive heating layer 24 may be a printed heater. The at least one electrically insulative barrier defines the first and second types of electrical track. The electrically insulative barrier defines a barrier to electrical conduction across the barrier.

The insulative barrier may be an air gap. In embodiments, the insulative barrier is a filled gap, for example filled with an insulative material. The barrier defines a barrier to electrical conduction across the barrier.

The or each resistive heating element 60 defining the resistive heating layer 24 may be formed by a cutting action. Cutting may include die cutting. The resistive heating element may be formed by an action applied to the resistive heating layer only. In embodiments, the resistive heating element may be formed by an action applied to the resistive heating layer and the support layer, for example an action of cutting the resistive heating layer and the support layer.

FIG. 7 shows an electrically conductive layer, indicated generally by the reference numeral 70, in accordance with an example embodiment. The electrically conductive layer 70 comprises a heating element 72, a first electrical connection 74 (e.g. a positive connection), and a second electrical connection 76 (e.g. a negative connection). As shown in FIG. 6, the heating elements 72 comprises a plurality of perforations (including perforations 73a, 73b, 73c etc.). The heating element 72 comprises a non-straight electrically conducting path between the first electrical connection 74 and the second electrical connection 76 (formed by cuts including cuts 78a and 78b and other similar cuts in the electrically conductive layer that separates the first and second heating elements). As with the heating element 60 described above, the meandering nature of the path of the heating element 72 increases the total length of the path between the first and second electrical connectors, such that the electrical resistance of the path is increased (when compared with a straight, direct, path between the first and second electrical connectors). This is in addition to the increased electrical resistance as a result of the plurality of perforations. Thus, the electrical resistance of the heating element 72 may be dependent on the length of the electrically conducting path and on the nature of the perforations in the conductive layer (e.g. the size, quantity and distribution of the perforations). In embodiments, the electrical resistance of each heating element 72 of the plurality of heating elements may vary. Each heating element of the plurality of heating elements may have the same electrical resistance. At least one resistive heating element of the plurality of heating elements may have a different electrical resistance to another one of the resistive heating elements. The electrical resistance of the electrical connections of each of heating element may vary. The electrical resistance of each heating element may be varied dependent on the electrical resistance of the associated electrical connections, such that the total electrical resistance of the electrical connections and the heating element is the same for each portion of the electrically conductive layer 24. In embodiments, each heating element has the same plurality of perforations. At least one resistive heating element may have a different plurality of perforations to another one of the heating element. The plurality of surface features of at least one heating element has a different at least one of size, quantity and distribution of perforations to another one of the heating elements. The electrical resistance of the heating elements may be adjusted, configured or tuned in accordance with requirements of the heating element. Advantageously, heating elements with different electrical resistance can provide different heating properties that can provide a different experience for the user. In one example, the heating elements can be configured to each heat a portion of material that is a different composition to one or more of the other portions. The heating elements may be configured to each have different temperature profiles. The electrically conductive layer 70 may be used as the electrically conductive layer 24 of the aerosol generator 20 or 30 (or some similar aerosol generator) such that the electrically conductive paths of the heating element 72 can be used for resistive heating of an aerosolisable material to generate an aerosol.

FIG. 8 shows an electrically conductive layer, indicated generally by the reference numeral 80, in accordance with an example embodiment. The electrically conductive layer 80 is an example implementation of the heating element 24 of the aerosol generator 20 or 30 described above.

The electrically conductive layer 80 is formed into a plurality of heating elements, indicated generally by the reference numerals 81 to 85. Each of the heating elements 81 to 85 comprising a non-straight path extending from an electrical connection of a first type (the connections 86a to 86e respectively) to an electrical connection of a second type (the connection 88). Thus, the electrically conductive layer 80 provides a plurality of heating elements similar to the heating elements 60 and 72 described above. Note that the electrically conductive layer 80 may comprise perforations (not shown) in a similar manner to the electrically conductive layer 70 described above. When the layer 80 is used as the heating element 24 of the aerosol generator 20 or 30, each of the heating elements 81 to 85 provides an electrically conductive path for resistive heating of a portion of the aerosolisable material 22 to generate an aerosol at the respective portion of the support. The separate electrical connections of the first type 86a to 86e enable an electric current to be individually provided to each of the plurality of heating elements 81 to 85. Thus, the heating of different zones of an aerosolisable material can be controlled. For example, an aerosol generator may be provided with five aerosol generating zones. The layer 80 allows each of those zones to be activated separately. Thus, for example, five puffs of aerosol may be generated from a single consumable incorporating the heating elements 81 to 85.

Accordingly, for example, five puffs of aerosol may be generated from a single consumable incorporating a single aerosol generator 20 or 30, and ten puffs of aerosol may be generated from a single consumable incorporating two aerosol generators 20 or 30.

In the example electrically conducting layer 80, a plurality of electrical connections 86a to 86e of the first type (e.g. a positive electrical connection) are provided and a single connection of the second type 88 (e.g. a negative electrical connection) is provided.

This is not essential to all implementations. For example, multiple connections of the second type could be provided. In embodiments each resistive heating element 81 to 85 comprises a corresponding one of the first type of electrical contact 86a to 86e and a corresponding one of the second type of electrical contact 88.

In the example electrically conducting layer 80, the electrical connections of the first type are arranged on a first edge of the electrically conductive layer and electrical connections of the second type are arranged on a second edge of the electrically conductive layer. This may allow for convenient connection of electrical power, but, of course, many other configurations are possible, some of which are discussed further below.

FIG. 9 shows an electrically conductive layer, indicated generally by the reference numeral 90, in accordance with an example embodiment. The electrically conductive layer 90 is an example implementation of the heating element 24 of the aerosol generator 20 or 30 described above.

The electrically conductive layer 90 comprises a heating element 92, a first electrical connection of a first type 94, a second electrical connection of the first type 95, a first electrical connection of a second type 96 and a second electrical connection of the second type 97. In some example embodiments, the electrical connections of the first type provide positive electrical connections and the electrical connections of the second type provide negative electrical connections.

The heating element 92 has a higher electrical resistance than the electrical connections 94 to 97. This may be caused, at least in part, by the heating element 92 having perforations (not shown in FIG. 9). In use, an electrical current can flow from the electrical connection 94 to the electrical connection 96 via the electrically conductive layer 92. Similarly, an electrical current can flow from the electrical connection 95 to the electrical connection 97 via the electrically conductive layer 92. The higher resistivity of the heating element 92 (compared with the electrical connections) tends to restrict the flow of current between the electrical connections 94 and 97 and between the electrical connections 95 and 96. As a result, the electrically conductive layer 90 can be separated into different zones that can be heated separated (to a certain degree).

FIG. 10 is a flow chart showing an algorithm, indicated generally by the reference numeral 100, in accordance with an example embodiment.

The algorithm 100 starts at operation 102, where an electrically conductive layer is formed into one or more heating elements (e.g. a plurality of heating elements), wherein each heating element extends from an electrical connection of a first type to an electrical connection of a second type.

In other words, each heating element is at least a portion of a respective electrically conductive path between a respective electrical connection of the first type and the electrical connection of the second type. Such an electrically conductive layer may be considered to be a blank. The blank may be used to form an aerosol generator.

The formation of the or each heating element may occur prior to or post application of the electrically conductive layer on a support, where a support is present. The electrically conductive layer may be adhered to the support, or mounted or formed on the support in a different configuration.

In use, the or each heating element may be used to provide an electrically conductive path for resistive heating of a portion of an aerosolisable material to generate an aerosol. The electrically conductive layer may be perforated; alternatively, a perforation process may be provided (as discussed further below). At operation 104, an aerosolisable layer, including an aerosolisable material, is added, for example by placing the formed electrically conductive layer into contact with the aerosolisable layer. Said another way, at operation 104, at least one of the formed resistive heating layer and the aerosol generating layer is placed in contact with other component, wherein said aerosol generating layer incorporates aerosol generating material. In addition, or alternatively, the aerosol generating layer is formed on the resistive heating layer. The combination of the heating elements and the aerosolisable layer may be placed into contact with a support in an optional operation 106.

Thus, the algorithm 100 may be used to produce the aerosol generators 20 or 30 described above (for example incorporating the one of the electrically conducting layers 40, 50, 70, 80 or 90 described above).

FIG. 11 is a flow chart showing an algorithm, indicated generally by the reference numeral 110, for forming an aerosol generator in accordance with an example embodiment. In the algorithm 110, an electrically conductive layer is perforated before the heating elements placed into contact with an aerosolisable layer.

The algorithm 110 starts at operation 112 where a perforated conductive layer is obtained. The operation 112 may be implemented by sourcing electrically conductive material that has already been perforated or by perforating a conductive material as an initial step (i.e. including an act of perforation).

In operation 114, a perforated electrically conductive layer is combined with an aerosolisable layer, for example by placing a formed (and perforated) electrically conductive layer into contact with an aerosolisable layer, wherein said aerosolisable layer incorporates aerosolisable material (e.g. in the form or a gel), as discussed above.

The combination of the perforated heating element(s) and the aerosolisable layer may be placed into contact with a support in an optional operation 116. FIG. 12 is a flow chart showing an algorithm, indicated generally by the reference numeral 120, in accordance with an example embodiment.

The algorithm 120 starts at operation 122 where an electrically conductive layer is combined with an aerosolisable layer, for example by placing a formed electrically conductive layer into contact with an aerosolisable layer, wherein said aerosolisable layer incorporates aerosolisable material, as discussed above.

At operation 124, perforations are formed in the electrically conductive layer of the heating elements. The operation 124 may include forming perforations in the aerosolisable layer.

The combination of the heating elements and the aerosolisable layer may be placed into contact with a support in an optional operation 126.

FIG. 13 is a flow chart showing an algorithm, indicated generally by the reference numeral 130, in accordance with an example embodiment.

The algorithm 130 starts at operation 132 where an electrically conductive layer is combined with an aerosolisable layer, for example by placing a formed electrically conductive layer into contact with an aerosolisable layer, wherein said aerosolisable layer incorporates aerosolisable material, as discussed above. The operation 132 is therefore the same as the operation 122 described above. At operation 134, the combination of the heating elements and the aerosolisable layer are placed into contact with a support in operation 134.

At operation 136, perforations are formed in the electrically conductive layer of the heating elements. The operation 124 may include forming perforations in the aerosolisable material and/or the support.

In instances of the algorithms 100 to 130 described above in which perforations are provided in both an electrically conductive layer and an aerosolisable layer, those perforations may be similar in the two layers. However, this is not essential to all example embodiments. As discussed above, perforations in the electrically conductive layer may be provided to adjust the electrical resistance of that layer. In contrast, perforations in the aerosolisable layer may be provided to enable gas to escape from the layer (acting as a vent). The peroration of the aerosolisable layer may assist, in some example embodiments, with reducing delamination of the layers of an aerosol generator. It is not essential to all example embodiments that the perforations in the two layers are the same. For example, the quantity and pattern of the perforations may be different. Thus, for example, in the algorithms 120 and 130, a perforated electrically conductive layer may be formed together with a non-perforated aerosolisable layer in operations 122 or 132, and further perforations may be provided in both layers in operations 124 or 136. Similarly, in the algorithm 110, differently perforated layers may be obtained (for example in the operation 112).

In addition to enabling the electrical resistance of an electrically conductive layer to be modified, the provision of perforations in an aerosol generator comprising an aerosolisable layer and a support can be that the aerosolisable material (e.g. a gel) may be able to form a physical bond with the support (if provided) through the perforations in the electrically conductive layer. This may assist with the physical connection of the layers and reduce the risk of delamination of the aerosol generator layers. Indeed, in some example embodiments, perforation of the aerosolisable layer may be omitted as a result of a reduction in the risk of delamination.

FIG. 14 shows an aerosol generator, indicated generally by the reference numeral 140, being formed in accordance with an example embodiment. The aerosol generator 140 comprises an electrically conductive layer 142 and an aerosolisable layer 144 incorporating an aerosolisable material. The aerosolisable material may, for example, be formed on the layer 144 by depositing aerosolisable material, for example by spraying, painting, dispensing or in some other way.

The electrically conductive layer 142 is formed into one or more heating elements in an example implementation of the operation 102 of the algorithm 100 described above.

The electrically conductive layer 142 may, for example, be one of the electrically conducting layer 40, 50, 60, 70, 80 or 90 described above.

The electrically conducting layer 142 and the aerosolisable layer 144 are placed in contact with one another (as indicated by the arrow 146), in an example implementation of the operations 104, 114, 122 or 132 of the algorithms described above. The electrically conductive layer 142 may include perforations, which may be formed into the layer 142 before or after the layer 142 is placed in contact with the support 144 (as discussed above). The aerosolisable layer 144 may or may not have perforations, as discussed above.

FIG. 15 shows an electrically conductive layer 150 being formed in accordance with an example embodiment. The electrically conductive layer 150 is being cut using a laser cutter 152. The cutting of the electrically conductive layer 150 can be used to form the paths of the heating elements described herein. The electrically conductive layer 150 may include perforations (not shown) as discussed above.

The use of the laser cutter 152 (or some other cutting process) is not the only method by which the electrically conductive layers described herein may be generated. Some example methods are described below.

FIG. 16 is a flow chart showing an algorithm, indicated generally by the reference numeral 160, in accordance with an example embodiment. The algorithm 160 starts at operation 162, where an electrically conductive layer is provided. At operation 164, one or more heating elements are formed in the electrically conductive layer by chemically etching the electrically conductive layer. The operations 162 and 164 are an example implementation of the operation 102 of the algorithm 100 described above. The electrically conductive layer is then placed in contact with an aerosolisable layer, thereby implementing the operation 104 described above.

The flow chat of Figure 16 may also be referred to as showing part of a method of forming an aerosol generator 20, 30, 70 or an algorithm. In embodiments, the method or algorithm 160 starts at operation 162, where the resistive heating layer is provided. At operation 164, one or more of the resistive heating elements are formed in the resistive heating layer by chemically etching the resistive heating layer. The operations 162 and 164 are an example implementation of the operation 62 of the method 60 described above. The aerosol generating material is then disposed on the resistive heating layer, thereby implementing the operation 104 described above. FIG. 17 is a flow chart showing an algorithm, indicated generally by the reference numeral 170, in accordance with an example embodiment.

The algorithm 170 starts at operation 172, where heating elements are formed, at last in part, by printing an electrically conductive layer. The operation 172 is therefore an example implementation of the operation 102 of the algorithm 100 described above. The electrically conductive layer is then placed in contact with an aerosolisable layer, thereby implementing the operation 104 described above. The flow chat of Figure 17 may also be referred to as showing part of a method of forming an aerosol generator 20, 30, 70 or an algorithm, indicated generally by the reference numeral 170. The method or algorithm 170 starts at operation 172, where one or more heating elements are formed, at last in part, by printing a resistive heating layer. The operation 172 is therefore an example implementation of the operation 162 of the algorithm 160 described above. The aerosol generating material is then disposed on the resistive heating layer, thereby implementing the operation 104 described above.

The cutting, etching and printing methods described above are provided by way of example; alternative methods are also possible. For example, a so-called “hot foiling” approach could be used in which a heating element is made out of an electrically conductive layer, and then assembled/bonded onto a substrate. Yet other techniques could be used, such as die cutting or punch holes (e.g. perforations) into the electrically conductive layer. Moreover, two or more technologies could be combined (e.g. electrical conductivity could be added to connection traces by adding more conductive material, such as additional foil, printed material, etc.). The skilled person will be aware of many further technologies, or combinations of technologies, that could be used in implementations of the principles described herein. FIG. 18 is a flow chart showing an algorithm, indicated generally by the reference numeral 180, in accordance with an example embodiment. The algorithm 180 may, for example, be implemented using any of the aerosol generators described herein.

The algorithm 180 is initiated when an instruction to activate heating is received in an instance of operation 182. In response to the instruction to activate heating, a determination is made (in operation 184) regarding whether a heating element is available. As discussed above, a plurality of heating elements may be provided by electrically conductive layers described herein. The operation 184 may involve determination which of the heating elements have been used (and the corresponding available aerosolisable material used up).

If a heating element is available, the algorithm moves to operation 186, where an available heating element is used. As discussed above, heating elements may be individually controllable, for example by providing electrical power to individual heating elements. Once the operation 186 is complete, the algorithm terminates at operation 188.

If, at operation 184, a determination is made that no heating elements are available (e.g. because all heating elements have been used), then the algorithm terminates at operation 188. This may mean that a consumable part being used to implement the algorithm 180 needs to be replaced.

FIG. 19 shows an electrically conductive layer, indicated generally by the reference numeral 190, in accordance with an example embodiment. The electrically conductive layer 190 may be formed using a laser cutter (similar to the laser cutter 152 described above), or some similar device, although other methods could be used (such as chemical etching or printing, as discussed above). The electrically conductive layer 190 may comprise perforations, as discussed above. Said another way, the resistive heating layer 190 may be formed using the laser cutter 152 described above, or some similar device or another method. Each resistive heating element extends from one of the first type of electrical contact, for example a positive electrical contact, to the second type of electrical contact, for example a negative electrical contact.

The electrically conductive layer 190 comprises a plurality of heating elements, each heater element being a linear heating element comprising a conducting path extending across a length of the support. Each heating element extends from an electrical connection of the first type (e.g. a positive electrical connection) to an electrical connection of the second type (e.g. a negative electrical connection). In the example layer 190, both types of electrical connection are provided at the same end of the layer and are provided next to each other. Thus, the example paths of the layer 190 extend from one end of the layer to the other and back again. Note that there is no common second connection as is some other example embodiments; instead, each heating element has separate first and second electrical connections.

FIG. 20 shows an electrically conductive layer, indicated generally by the reference numeral 200, in accordance with an example embodiment. The electrically conductive layer 200 may be formed using a laser cutter (similar to the laser cutter 152 described above), or some similar device, although other methods could be used (such as chemical etching or printing, as discussed above). The electrically conductive layer 200 may comprise perforations, as discussed above. The electrically conductive layer 200 comprises a plurality of heating elements, each heater element being a linear heating element comprising a conducting path extending across a length of the support. Each heating element extends from an electrical connection of the first type (e.g. a positive electrical connection) to an electrical connection of the second type (e.g. a negative electrical connection). In the example layer 200, the types of electrical connection are provided at the opposite ends of the layer and a common second (negative) connection is provided. Although a linear path is provided (rather than a meandering path), electrical resistance is provided by means of providing a crenelated path. Note that the paths of any other embodiments described herein could also be crenelated.

FIG. 21 shows part of an aerosol generator 210 in accordance with an example embodiment. As discussed above, the aerosol generator 210 may comprise an electrically conductive layer having plurality of electrical connections of a first type (e.g. providing positive electrical connections to each of a plurality of heating elements) and a single electrical connection of a second type (e.g. providing a common negative electrical connection to the plurality of heating elements).

Said another way, the article 300 has an article electrical contact configuration. The electrical contact configuration in embodiments is formed by the aerosol generator 210. The electrical contact configuration comprises heater electrical contacts 212, 214. The heater electrical contacts may also be known as heater or article contacts 212, 214.

The aerosol provision device comprises an electrical connector 220 as shown in Fig. 22. The electrical connector comprises connector electrical contacts. The connector electrical contacts may also be known as connector or device contacts. The article electrical contact configuration is configured to electrically communicate with the device electrical connector 220.

The first and second types of electrical contacts 62, 63, namely the heater contacts, together form at least part of the article electrical contact configuration of the aerosol generator 20, 30, 70.

The resistive heating elements 60 are on an inner side of the resistive heating layer.

The inner side defines the first side of the aerosol generator 210. The heater contacts 62, 63 are on the second side of the resistive heating layer. The second side defines an outer side of the aerosol generator 210. The heater contacts are exposed so that they are able to be brought into contact with the device electrical connector. The heater contacts are on an opposing side of the resistive heating layer to the resistive heating elements. Other configurations are envisaged. The support layer 32 is between an inner portion of the resistive heating layer and an outer portion of the resistive heating layer.

The configuration of the article 300 may vary. The article 300 comprises a body 302.

The body 302 may be hollow. The body 302 may define a flow path through the article 300. The flow path extends between the air inlet and the aerosol outlet. The flow path is defined by an internal space in the article along which air and/or aerosol can flow. The flow path is defined in the body 302. The or each aerosol generator 210 bounds the flow path. The aerosol generating material is exposed to the flow path. The aerosol generating material is exposed in the internal space. The internal space in embodiments comprises two or more chambers.

In Figure 21 , the distal end of the article 300 is shown. As shown, the body 302 comprises a plurality of body layers. The body layers are arranged in a stack of body layers 304. The body layers form a laminate. The body layers in embodiments are card layers. Other suitable materials may be used. The body layers 304 are configured to define features of the article 300. At least one body layer in embodiments comprises a gap defining an air inlet. The gap defines an opening 306.

The air inlet comprises the opening 306. The opening is formed in the body 302. In embodiments, the opening 306 is formed in another component of the article 300, for example the aerosol generator 210 or another wall feature. The aerosol outlet comprises an outlet opening. The outlet opening is formed in the body 302. In embodiments, the outlet opening is formed in another component of the article 300, for example the aerosol generator 210 or another wall feature.

In embodiments, the article 300 may comprise two aerosol generators 210 forming an aerosol generator arrangement. The number of aerosol generators 210 may differ. Each aerosol generator 210 comprises aerosol generating material. The aerosol generating material is exposed to the flow path. In embodiments the article 300 comprises a single aerosol generator 210.

The aerosol generator 210 comprises a plurality of external connectors, the configuration of the external connectors being dependent on the configuration of the first and second type of electrical connections of the aerosol generator. For example, the aerosol generator as shown in FIG. 21 comprises a plurality of external connectors, indicated by the reference numeral 212 (each connected to one of the electrical connections of the first type) and a further external connector 214 (connected to the electrical connection of the second type). The aerosol generator 210 may have further external connectors corresponding to the connectors 212 and 214 on the underside of the device (not visible in FIG. 21).

FIG. 22 shows a connector 220 used in some example embodiments. The connector has separate pins for connection with electrical contacts, such as the connectors 212 and 214 described above.

FIG. 23 is a block diagram of an aerosol generating device, indicated generally by the reference numeral 230, in accordance with an example embodiment. The system comprises the aerosol generator 230 described above, first and second connectors 220a and 220b (similar to the connector 220 described above) and a control section 232. The control section 232 is similar to the control section 2 of the aerosol generating device 10 described above with reference to FIG. 1. The aerosol generator 210 is similar to the consumable part 4 of the aerosol generating device 10. The connectors 220a and 220b enable the control section 232 to provide regulated or controlled electrical voltages and/or currents to the various electrical connections of the first and second type of the aerosol generator 210 when the aerosol generator 210 is inserted into the control section 232 (as shown in FIG. 23). The control section 232 may, for example, implement the algorithm 180 described above.

In some embodiments of the different arrangements of aerosol generators and articles described above the aerosol generating material is formed in a configuration other than as an aerosol generating layer. The aerosol generating material in embodiments is in the form of an aerosol generating segment. The aerosol generating segment generally comprises a solid material. Such a solid material may be shredded tobacco. The aerosol generating material, arranged as an aerosol generating segment for example, may comprise a plurality of individual pieces of aerosol generating material. The aerosol generating material may be individual pieces of tobacco material. In embodiments, the aerosol generating material comprises a plurality of strips, beads or pellets. In embodiments the aerosol generating segment is a plug of material.

The aerosol generating segment in embodiments comprises a body of material. The aerosol generating material is a non-liquid. In such an embodiment, the body of material comprises a rod of aerosol generating material, for example a tobacco rod. For example, the body of material may comprise shredded tobacco material. The body of material may be formed into a rod. In some embodiments, the body of material comprises cut rag tobacco that is formed into a rod. The aerosol generating material may comprise tobacco material. The aerosol generating material may comprise extruded tobacco. The aerosol generating material may comprise reconstituted tobacco.

The aerosol generating material, formed as a solid material, may comprise nicotine. The aerosol generating material may comprises, consist of, or essentially consist of, tobacco. In embodiments, the aerosol generating material is free from tobacco. In embodiments of any of the above, the heating of the article provides a relatively constant release of volatile compounds into an inhalable medium. In an embodiment of the above, the aerosol generating segment is a plug of material. The article may comprise a mouth end section. A tubular element may be located between the aerosol generating material and the mouth end section. The article may comprise a ventilation area in the mouth end section. The mouth end section may define a mouthpiece configured to be placed between a user’s lips.

In embodiments of any of the above described articles, the or each resistive heating element is configured to heat substantially the entire aerosol generating material. The aerosol generating segment in embodiments is at least substantially cylindrical. In embodiments, the aerosol generating segment is at least partially wrapped by the resistive heating layer. In embodiments, the resistive heating element extends in the aerosol generating segment. The resistive heating element may extend around the aerosol generating segment. In embodiments, the resistive heating element encircles the aerosol generating segment. In some arrangements at least a portion of the flow path through the article is through the aerosol generating segment. The aerosol generating segment may define part of the air path. In embodiments, the first type of electrical contact and the second type of electrical contact are exposed from the aerosol generating segment.

The aerosol generating material may comprise tobacco material as described herein, which includes a tobacco component. In the tobacco material described herein, the tobacco component may contain paper reconstituted tobacco. The tobacco component may also contain leaf tobacco, extruded tobacco, and/or bandcast tobacco. The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco can be formed from a mixture of forms of tobacco material, for instance a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco and bandcast tobacco. In embodiments, the tobacco material comprises paper reconstituted tobacco or a mixture of paper reconstituted tobacco and leaf tobacco. In the tobacco material described herein, the tobacco material may contain a filler component. The filler component is generally a non-tobacco component, that is, a component that does not include ingredients originating from tobacco. The filler component may be a non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler component may also be an inorganic material such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. The filler component may be present in an amount of 0 to 20% by weight of the tobacco material, or in an amount of from 1 to 10% by weight of the composition. In some embodiments, the filler component is absent. In the tobacco material described herein, the tobacco material contains an aerosol-former material. In this context, an "aerosol-former material" is an agent that promotes the generation of an aerosol. An aerosol-former material may promote the generation of an aerosol by promoting an initial vaporisation and/ or the condensation of a gas to an inhalable solid and/ or liquid aerosol. In some embodiments, an aerosol-former material may improve the delivery of flavour from the aerosol generating material. In general, any suitable aerosol-former material or agents may be included in the aerosol generating material of the invention, including those described herein.

Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco feedstock is extracted with a solvent to afford an extract of solubles and a residue comprising fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with fibrous material from the residue (usually after refining of the fibrous material, and optionally with the addition of a portion of non-tobacco fibres) by deposition of the extract onto the fibrous material. The process of recombination resembles the process for making paper.

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. An aerosol generator of an article for an aerosol provision device, the aerosol generator comprising: aerosol generating material; and a resistive heating layer comprising a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol; wherein the resistive heating element is at least a portion of an electrically conductive path between an electrical contact of a first type and an electrical contact of a second type; and wherein the resistive heating layer comprises a plurality of surface features.

2. The aerosol generator of claim 1 , wherein the plurality of surface features comprise a plurality of perforations.

3. The aerosol generator of claim 1 or claim 2, wherein the plurality of surface features comprise at least one of a plurality of indents and a plurality of protrusions.

4. The aerosol generator of any of claims 1 to 3, wherein at least some of the surface features are formed along the electrically conductive path.

5. The aerosol generator of claim 4, wherein the plurality of surface features are configured to at least partially determine the electrical resistance along the electrically conductive path.

6. The aerosol generator of any of claims 1 to 5, comprising an array of the surface features.

7. The aerosol generator of any of claims 1 to 7, comprising an aerosol generating layer including the aerosol generating material.

8. The aerosol generator of claim 7, wherein the aerosol generating layer comprises a plurality of aerosol generating layer perforations.

9. The aerosol generator of claim 8, wherein the plurality of surface features of the resistive heating layer are aligned with the plurality of aerosol generating layer perforations.

10. The aerosol generator of any of claims 7 to 9, wherein the aerosol generating layer is free from perforations.

11. The aerosol generator of any of claims 1 to 10, comprising a support configured to support the resistive heating layer.

12. The aerosol generator of claim 11 , wherein the support is free from perforations.

13. The aerosol generator of claim 11 , wherein the support comprises a plurality of support perforations.

14. The aerosol generator of claim 13, wherein the plurality of surface features of the resistive heating layer are aligned with the plurality of support perforations.

15. The aerosol generator of any of claims 1 to 16, wherein at least one resistive heating element has at least one of a different electrical resistance to another one of the resistive heating elements and a different plurality of surface features to another one of the resistive heating elements.

16. An aerosol generator comprising: an aerosolisable layer incorporating an aerosolisable material; and an electrically conductive layer in contact with said aerosolisable layer, wherein said electrically conductive layer comprises a plurality of perforations and wherein said electrically conductive layer comprises one or more heating elements, the or each heating element providing an electrically conductive path for resistive heating of a portion of said aerosolisable material to generate an aerosol, wherein the or each heating element extends from an electrical connection of a first type to an electrical connection of a second type.

17. An article comprising an aerosol generator of any one of claims 1 to 16.

18. An aerosol provision device configured to receive an aerosol generator of any one of claims 1 to 16 or an article of claim 17.

19. An aerosol provision system comprising: an aerosol generator of any one of claims 1 to 16 or an article of claim 17; and an aerosol provision device configured to receive the aerosol generator or the article.

20. A blank for forming an aerosol generator of an article for an aerosol provision device comprising: a resistive heating layer, wherein the resistive heating layer forms a heating element, the heating element providing an electrically conductive path for resistive heating; an electrical contact of a first type; and an electrical contact of a second type; wherein the heating element extends between the electrical contact of the first type and the electrical contact of the second type, and wherein the resistive heating layer comprises a plurality of surface features.

21. A method comprising: forming a resistive heating layer comprising a resistive heating element; providing aerosol generating material on the resistive heating layer; wherein the resistive heating element is configured to heat at least a portion of the aerosol generating material to generate an aerosol; wherein the resistive heating element is at least a portion of an electrically conductive path between an electrical contact of a first type and an electrical contact of a second type; and forming a plurality of surface features on the resistive heating layer.

22. A method comprising: forming an electrically conductive layer into a one or more heating elements, the or each heating element providing an electrically conductive path for resistive heating of a portion of an aerosolisable material to generate an aerosol; and placing the formed electrically conductive layer in contact with an aerosolisable layer, wherein said aerosolisable layer incorporates said aerosolisable material, wherein: the or each heating element extends from an electrical connection of a first type to an electrical connection of a second type; and said electrically conductive layer comprises a plurality of perforations.