WO2025056556A1 - Aerosol provision device - Google Patents

Abstract

Aerosol provision device (200) comprising: a housing part (506a) at least partially defining a cavity (206) shaped to receive an article (300) comprising: an aerosol generating material, article electrical contacts (322) and a heating arrangement (312) comprising a resistive heating element (342). The housing part defines a component receiving portion (511a) shaped to receive an electrical component (510a) of the device. The housing part comprises apertures (541) extending from the cavity to the component receiving portion. The device further comprises electrical contact elements (512) which extend through the apertures to engage an electrical component in the component receiving portion and to engage with the article electrical contacts when an article is in the cavity. The device comprises a sealing member (508a) arranged to seal the apertures. The electrical contact elements comprise a pointed tip (539) configured to pierce the sealing member.

Description

AEROSOL PROVISION DEVICE

Technical Field

The present invention relates to an aerosol provision device. The present invention also relates to a method of manufacturing at least part of an aerosol provision device.

Background

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

Aerosol provision systems, which cover the aforementioned devices or products, are known. Common systems use heaters to create an aerosol from a suitable medium which is then inhaled by a user. Often the medium used needs to be replaced or changed to provide a different aerosol for inhalation. It is known to use resistive heating systems as heaters to create an aerosol from a suitable medium.

Summary

According to an aspect, there is provided an aerosol provision device comprising: a housing part which at least partially defines: a cavity shaped to receive, during use, an article which comprises: an aerosol generating material, a plurality of article electrical contacts providing an electrical connection to the article, and a heating arrangement comprising at least one resistive heating element; and a component receiving portion shaped to receive an electrical component of the aerosol provision device; wherein the housing part comprises one or more apertures extending through a body of the housing part from the cavity to the component receiving portion; wherein the aerosol provision device further comprises: one or more electrical contact elements arranged to extend through the one or more apertures so as to engage an electrical component arranged within the component receiving portion and to engage with respective ones of the article electrical contacts when an article is received within the cavity; and at least one sealing member arranged to seal the one or more apertures; wherein each of the one or more electrical contact elements comprise a pointed tip configured to pierce the sealing member during assembly of the aerosol provision device such that the one or more electrical contact elements protrude through the sealing member so as to make an electrical connection with the electrical component.

According to another aspect, there is provided a method of manufacturing at least part of an aerosol provision device, the aerosol provision device comprising: a housing part which at least partially defines: a cavity shaped to receive, during use, an article which comprises: an aerosol generating material, a plurality of article electrical contacts providing an electrical connection to the article, and a heating arrangement comprising at least one resistive heating element; and a component receiving portion shaped to receive an electrical component of the aerosol provision device; wherein the housing part comprises one or more apertures extending through a body of the housing part from the cavity to the component receiving portion, the method of manufacture comprising: arranging one or more electrical contact elements, each having a pointed tip, to extend through the one or more apertures so as to engage an electrical component arranged within the component receiving portion and to engage with respective ones of the article electrical contacts when an article is received within the cavity; and then pressing at least one sealing member into a position in which the one or more apertures are sealed, and the pointed tips of the one or more electrical contact elements pierce the sealing member such that the one or more electrical contact elements protrude through the sealing member so as to make an electrical connection with electrical component; or the method of manufacture comprising: sealing the one or more apertures with at least one sealing member; and then inserting one or more electrical contact elements, each having a pointed tip, through the one or more apertures and piercing the sealing member with the pointed tips of the one or more electrical contact elements such that the one or more electrical contact elements protrude through the sealing member so as to make an electrical connection with the electrical component.

The plurality of article electrical contacts may comprise a plurality of heater electrical contacts providing an electrical connection to the at least one heating element.

The housing part may be formed from a polymeric material.

The housing part may be formed from an injection moulded polymer. The at least one sealing member may comprise (e.g. be made up of) a plurality of

(e.g. sub) sealing members, and wherein each (sub) sealing member seals at least one of the plurality of apertures.

The aerosol provision device may further comprise an electrical component, comprising a plurality of component electrical contacts, arranged within the component receiving portion and the plurality of electrical contact elements may engage with corresponding ones of the component electrical contacts.

The electrical component may comprise a printed circuit board.

The aerosol provision device may further comprise one or more fasteners configured to secure the electrical component against the at least one sealing member.

The at least one sealing member may comprise a sheet of flexible material (e.g. silicone, Thermoplastic polyurethane (TPU), Thermoplastic elastomer (TPE), or any other suitable flexible material).

The sealing member may be overmoulded onto the first housing part.

The housing part may be configured to retain a battery. The aerosol provision device may comprise a further (e.g. second) housing part, and the first and second housing parts may together define the cavity.

The second housing part may comprise one or more of the features of the first housing part described herein.

The aerosol provision device may comprise a cover, and the cover and the housing part may together define the component receiving portion. The housing part may further define a sealing member receiving portion (e.g. inside the component receiving portion) shaped to receive at least part of the at least one sealing member.

The heating arrangement may comprise an electrically conductive layer formed into the one or more heating elements.

At least a portion of the electrically conductive layer may form a resistive heating element configured to heat at least a portion of the aerosol generating material to generate an aerosol.

The one or more heating elements may be configured to resistively heat at least a portion of the aerosol generating material to generate an aerosol.

The electrically conductive layer may further comprise electrical tracks extending from the heating element.

The electrical tracks may extend to or provide the article (e.g. heater) electrical contacts. The method may comprise placing the one or more electrical contact elements on an assembly block to align the one or more electrical contact elements with the one or more apertures before inserting the one or more electrical contact elements through the one or more apertures. The assembly block may comprise one or more fixture pins which are configured to engage with the one or more electrical contact elements, and with the housing part. The one or more electrical contact elements may each comprise a hole configured to receive the one or more fixture pins when the one or more first electrical contact elements are placed on the assembly block.

The hole may be a through hole extending through entire depth of the one or more electrical contact elements.

The housing part may comprise one or more alignment holes configured to receive the one or more fixture pins when the one or more first electrical contact elements are inserted through the one or more apertures.

The alignment hole may be a blind hole. The method may further comprise arranging an electrical component within the component receiving portion, fixing the one or more electrical contact elements to the electrical component, and then removing the assembly block.

The method may comprise soldering the one or more electrical contact elements to the electrical component.

The method may comprise forming the housing part (e.g. via injection moulding).

In an embodiment of any of the above, the plurality of article electrical contacts comprises a first type of electrical contact and a second type of electrical contact.

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 material comprises an aerosol generating layer. In embodiment of any of the above, the heating arrangement and aerosol generating material together form an aerosol generator. In an embodiment of any of the above, the heating arrangement comprises a resistive heating layer. In an embodiment of any of the above, the aerosol generator comprises a support configured to support the resistive heating layer.

In an embodiment of any of the above, 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 material. 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, the first type of electrical contact is configured to electrically connect with a device electrical connector (e.g. electrical contact element) and the second type of electrical contact is configured to electrically connect with the device electrical connector (e.g. electrical contact element).

In an embodiment of any of the above, the support defines an exposed contact area of the first type of electrical contact.

In an embodiment of any of the above, wherein the exposed contact area is a first exposed contact area, and the support defines a second exposed contact area of the second type of electrical contact.

In an embodiment of any of the above, the aerosol generating material is a continuous aerosol generating material. 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 material is a discontinuous aerosol generating material. 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 material comprises a plurality of discrete aerosol generating portions. 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 element is one of a plurality of resistive 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 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 layer. 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 electrical contact of the first type. 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 said resistive heating layer; chemically etching said resistive heating layer; forming or pressing the resistive heating layer in the substrate; and printing said resistive heating layer.

In an embodiment of any of the above, wherein the resistive heating layer is in the form of a foil.

Brief Description of the Drawings

Various embodiments will now be described, by way of example only, with reference to the accompanying schematic drawings, in which: Figure 1 is a schematic perspective view of an aerosol provision system;

Figure 2 is a schematic perspective view of an article comprising aerosol generating material of the aerosol provision system of Figure 1;

Figure 3 is a schematic perspective view of a first side of an aerosol generator of the article of Figure 2; Figure 4 is a schematic perspective view of part of a second side of the aerosol generator of Figure 3;

Figure 5 is a schematic block diagram of an aerosol provision system such as the system shown in Figure 1;

Figure 6 is a schematic partially exploded perspective view of the article of Figure 2, with an aerosol generator shown inverted from an assembled orientation and in a spaced relationship with other components;

Figure 7 is a schematic cross-sectional view of another aerosol generator such as the aerosol generator shown in Figure 3;

Figure 8 is a schematic plan view of a heating element of the aerosol generator of Figure 3;

Figure 9 is a schematic plan view of a resistive heating layer of the aerosol generator of Figure 3 with a plurality of heating elements;

Figure 10 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3; Figure 11 is an exploded perspective view of an aerosol generator being formed;

Figure 12 is a schematic perspective view of a resistive heating layer of an aerosol generator being formed;

Figure 13 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3; Figure 14 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3; Figure 15 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3;

Figure 16 is a schematic perspective view of a resistive heating layer of an aerosol generator being formed; Figure 17 is a schematic plan view of a heating element of an aerosol generator;

Figure 18 is a schematic plan view of a heating element of an aerosol generator; Figure 19 is a schematic perspective view of part of an aerosol generator of the article of Figure 2;

Figure 20 is a schematic perspective view of a device connector of an aerosol provision device of the aerosol provision system of Figure 1 ;

Figure 21 is a schematic side view of the aerosol generating system of Figure 1 ;

Figure 22 is a flow chart showing a method of forming an aerosol generator, such as the aerosol generator of Figure 3; and

Figures 23 to 25 show an aerosol generator being formed; Figure 26 and 27 show another aerosol generator in plan view;

Figure 28 and 29 show a perspective view of another aerosol provision device;

Figures 30 and 31 show a perspective view of first and second housing parts of the aerosol provision device shown in Figure 28 and 29; Figures 32 and 33 show a perspective view of a first housing part shown in

Figures 30 and 31 ;

Figure 34 shows parts of an aerosol provision device shown in Figure 28 and 29 in exploded view;

Figure 35 shows a close-up perspective view of a section of a first housing part shown in earlier Figures;

Figure 36 shows a close-up perspective view of an electrical contact element shown in earlier Figures;

Figure 37 shows a perspective view of an assembly block for use in a method of manufacturing an aerosol provision device; Figure 38 is a flow chart showing a method of manufacturing part of an aerosol provision device, such as the aerosol provision device of Figure 29;

Figures 39 and 40 show a perspective view of part of an aerosol provision device being assembled;

Figure 41 shows a cross sectional view through part of an aerosol provision device. 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 aerosol-generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

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

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

In some embodiments, the disclosure relates to consumables comprising 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.

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.

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

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.

In embodiments, the aerosol-generating material comprises a plurality of aerosol- generating films. In embodiments, the aerosol-generating film comprises a plurality of aerosol-generating film regions. Such plurality of aerosol-generating films and/or plurality of aerosol-generating film regions may have different properties, for example at least one of different compositions, thicknesses, density, active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material. 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 aerosol-generating 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 aerosolgenerating 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.

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.

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 aerosolgenerating material storage area, an aerosol-generating material transfer component, an aerosol transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying 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 comprise a conductor which can be heated by the passage of an electrical current through the conductor. Noncombustible aerosol provision systems may comprise a modular assembly including both a reusable aerosol provision device and a replaceable aerosol generating article. In some implementations, the non-combustible aerosol provision device may comprise a power source and a controller (or control circuitry). The power source may, for example, comprise an electric power source, such as a battery or rechargeable battery. In some implementations, the non-combustible aerosol provision device may also comprise an aerosol generating component. However, in other implementations the aerosol generating article may comprise partially, or entirely, the aerosol generating component.

Figure 1 shows a schematic view of an aerosol provision system 100. The aerosol provision system 100 comprises an aerosol provision device 200 and an article 300 comprising aerosol generating material 302 (refer to Figure 3). The article 300 is shown in Figure 2 removed from the aerosol provision device 200. An aerosol generator 304 of the article 300 is shown in Figure 3 with a perspective view of a first side 306, with a perspective view of part of a second side 307 shown in Figure 4.

The article 300 comprises the aerosol generator 304. The aerosol generator 304 is configured to generate an aerosol from the aerosol generating material 302 upon operation of the aerosol provision system 100, as will be describe in detail below. The aerosol provision system 100 may be elongate, extending along a longitudinal axis. The aerosol provision system 100 has a proximal end 102, 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 100, and a distal end 104 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 100 accordingly defines a proximal direction, which is directed towards the user when in use. Further, the aerosol provision system 100 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 100 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.

The article 300 is received by the aerosol provision device 200. The configuration of the article 300 and the aerosol provision device 200 may vary. In the present embodiment, the aerosol provision device 200 comprises a device body 202. The device has a housing 204 enclosing components of the device 200. An article receiving portion 206, sometimes referred to as a device chamber, as shown in Figure 5, is configured to receive a portion of the article 300. A proximal end 308 of the article protrudes from the device 200 when the article 300 is received in the device chamber 206. A receptacle 208 defines the chamber 206. The receptacle 208 comprises a receptacle base 210 and a receptacle peripheral wall 212. The configuration of the receptacle 208 may vary in dependence on the configuration of the article 300.

One or more user-operable control elements 224, such as a button or switch, which can be used to operate the aerosol provision system 100 may be provided on the aerosol provision device 200. For example, a user may activate the system 100 by pressing the control element 224. The one or more user-operable control elements may be omitted. In embodiments, the aerosol provision system 100 is operated by another user action, for example puff activated by a user drawing air through the system. The aerosol provision device 200 comprises an opening 214 at the proximal end, leading into the device chamber 206. The opening 214 is provided in one end, through which the article 300 can be inserted. In embodiments, the article 300 may be fully or partially inserted into the device 200. The configuration of the device 200 may vary, for example the opening may be in a longitudinal side wall of the device 200, and/or may be closed by another feature of the device 200 during use. In the present configuration, the article 300 defines a mouthpiece 310 at the proximal end 308. In other embodiments, the device 200 defines the mouthpiece. The user places their mouth over the mouthpiece during use.

The device 200 defines the longitudinal axis along which an article 300 may extend when inserted into the device 200. The opening 214 is aligned on the longitudinal axis. The longitudinal axis may be an axis along which the article 300 is inserted into the device 200. The longitudinal axis may be considered to be a receiving axis of the device 200. The article 300 may similarly have a longitudinal axis along which it is inserted into the device and this axis may be considered to be an insertion axis. The aerosol provision device 200 comprises a power source 220. The power source 220 may be a battery, for example a rechargeable battery. The device 200 also comprises a control circuit 222, acting as a controller, comprising a processor and a memory. As discussed in detail below, a heating system 110 is configured to heat the aerosol generating material 302 of an article 300. The article 300 in embodiments is a consumable, and is interchangeable with other articles 300. The heating system 110 comprises the aerosol generator 304. The heating system 110 comprises other components of the aerosol provision system 100 including components of the article 300 and the aerosol provision device 200, for example the power source 220 and the control circuit 222.

The aerosol generator 304 forms part of the article 300. The aerosol generator 304 comprises a heating arrangement 312 configured to heat aerosol generating material 302, for example at least one of a film and a gel to generate an aerosol. The aerosol generating material may be referred to as aerosolisable material.

The heating arrangement 312 is a resistive heating arrangement. The or each heating element in embodiments is a resistive heating element, as described in detail below. In such arrangements the heating system 110 comprises a resistive heating generator including components to heat the heating arrangement 312 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 312 comprises electrical contacts for supplying electrical current to the resistive material. The provision of a resistive heating arrangement 312 allows for a compact arrangement. Resistive heating provides an efficient configuration.

In the use of the aerosol provision system 100, air is drawn into an air inlet 314 of the article 300, as indicated by arrow 316. The air inlet 314 is in a distal end of the article 300. In embodiments, the air inlet 314 may have a different configuration, for example in the side. The air flow to the air inlet 314 of the article 300 may be defined, for example by at least one of an air path through the device 200, an air path external to the device 200, and an air path between the device 200 and the article 300. An aerosol generated by the aerosol generator 304 exits the device at an aerosol outlet 318, as indicated by arrow 319. In embodiments the aerosol outlet 318 is in the mouthpiece of the article 300, such that the aerosol is drawn directly from the article 300 into the mouth of a user of the system 100. In some example embodiments, the aerosol provision system comprises two main components, namely a control section forming a reusable part and a consumable section forming a replaceable or disposable part which may be referred to as a replaceable or disposable article or cartridge. As described herein, the aerosol provision device 200 forms a control section and the article 300 forms the consumable section. In the use of the aerosol generating system, the control section and the consumable part may be releasably connected at an interface. The consumable part may be removable and replaceable, for example when the consumable part is used, with the control section being re-used with a different consumable part. The aerosol provision system 100 as shown is provided by way of example only and is highly schematic. Different 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, passes through the interface, and exits the consumable part. As shown schematically in Figure 5, and described in detail below, the article 300 has an article electrical contact configuration 320. The electrical contact configuration 320 in embodiments is formed by the aerosol generator 304. The electrical contact configuration 320 comprises heater electrical contacts 322. The heater electrical contacts 322 may also be known as heater or article contacts. The aerosol provision device 200 comprises an electrical connector 230. The electrical connector 230 comprises connector electrical contacts 232. The connector electrical contacts 232 may also be known as connector or device contacts. The article electrical contact configuration 320 is configured to electrically communicate with the device electrical connector 230.

The configuration of the article 300 may vary. The article 300 comprises a body 324. The body 324 is hollow. The body 324 defines a flow path 326 (refer to Figure 6) through the article 300. The flow path 326 extends between the air inlet 314 and the aerosol outlet 318. The flow path 326 is defined by an internal space in the article along which air and/or aerosol can flow. The flow path 326 is defined in the body 324. The or each aerosol generator 304 bounds the flow path 326. The aerosol generating material 302 is exposed to the flow path 326. The aerosol generating material 302 is exposed in the internal space. The internal space in embodiments comprises two or more chambers.

The air inlet 314 comprises an opening 315. The opening 315 is formed in the body 324. In embodiments, the opening is formed in another component of the article 300, for example the aerosol generator 304 or another wall feature. The aerosol outlet 318 comprises an outlet opening 317. The outlet opening 317 is formed in the body 324. In embodiments, the outlet opening 317 is formed in another component of the article 300, for example the aerosol generator 304 or another wall feature.

As shown in Figure 6, the article 300 comprises two aerosol generators 304 forming an aerosol generator arrangement. The number of aerosol generators 304 may differ. Each aerosol generator 304 comprises aerosol generating material 302. The aerosol generating material 302 is exposed to the flow path 326. In embodiments the article 300 comprises a single aerosol generator 304. One of the aerosol generators 304 will be described in detail, with such detail being applicable to one or more further aerosol generators 304 in embodiments.

The or each aerosol generator 304 and the body 324 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 304 defines a tubular configuration. Tubular may include circular cross-sectional, an elliptical cross section and other polygonal shapes.

In embodiments, as shown in the Figures, the article 300 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.

Figure 6 is a partially exploded perspective view of the article 300, with an aerosol generator 304 shown inverted from an assembled orientation and in a spaced relationship with other components. The article 300 comprises a first one of the aerosol generator 302, the body 324 and a second one of the aerosol generator. The body 324 spaces the first and second aerosol generators 304. The first and second aerosol generators 304 close the internal space defined by the body 324 along which air and/or aerosol can flow. The aerosol generating material 302 of the first and second aerosol generators 304 face each other and is exposed to the internal space. When assembled, the first and second aerosol generators 304 sandwich the body 324. In the embodiment of Figure 6 at least, the first and second aerosol generators 304 and the body have equal plan areas. In embodiments, one or more of the first and second aerosol generators 304 and the body 324 has a greater length and/or width. In embodiments, one of the first and second aerosol generators 304 is replaced by a blank panel. The body 324 comprises a body layer. The body may comprise a plurality of body layers. The body layers may be formed in a stack and arranged to define features of the article 300, such as the air inlet 314 and aerosol outlet 318.

A wrap encircles the article 300 and forms part of the article 300. The wrap may comprise a sheet. The wrap acts as a fixed sleeve. The or each aerosol generator 304 protrudes from the wrap at a distal end. Exposed electrical contact regions 323 of the heater contacts 322 are exposed at the distal end, for example refer to Figure 2. Other configurations are envisaged, for example at least one exposed electrical contact region 323 may additionally or alternatively be defined along a minor longitudinal face or edge of the article 300, and on a major face of the article defined by the aerosol generator 304. The aerosol generator 304 is schematically shown in cross section in Figure 7.

The aerosol generator 304 is an implementation of the aerosol generator 304 of the aerosol provision system 100 described above.

The aerosol generator 304 comprises an aerosol generating layer 330. The aerosol generating layer is also known as an aerosolisable layer. The aerosol generating layer 330 comprises the aerosol generating material 302. The aerosol generator 304 comprises a resistive heating layer 340. The resistive heating layer 340, in embodiments, is formed as an electrically conductive layer. The aerosol generating layer 330 is on the resistive heating layer 340. The aerosol generating layer 330 is in direct contact with the resistive heating layer 340. In embodiments, the aerosol generating layer 330 is in indirect contact with the resistive heating layer 340. The resistive heating layer 340 may in embodiments comprise a coating. As described in detail below, the resistive heating layer 340 comprises a plurality of resistive heating elements 342, for example as shown in Figures 8 and 9. The or each resistive heating element 342 forms at least a portion of an electrically conductive path between a pair of the electrical contacts 322. The or each resistive heating element 342 provides the electrically conductive path for resistive heating of at least of portion of the aerosol generating material 302 to generate an aerosol. The aerosol generating material 302 is, in embodiments, in the form of a film or a gel.

The resistive heating layer 340 is formed as an electrically conductive layer. This layer in embodiments takes the form of at least one of a metal layer, such as an aluminium layer, or a non-metallic material, such as graphene. The resistive heating layer 340 is in the form of a foil, for example an aluminium foil.

The aerosol generator 304 comprises a support 350. The support 350 in embodiments comprise a paper or card material. The support 350 provides structural support for the aerosol generator 304. The resistive heating layer 340 is on the support 350. The support 350 is configured as a support layer. As shown in Figure 7, in the aerosol generator 304, the resistive heating layer 340 is sandwiched between the support 350 and the aerosol generating layer 330. The support 350 is electrically insulative. The resistive heating layer 340 and the support layer 350 define a substrate 352. The substrate 352 supports the aerosol generating layer 330.

The article 300 may comprise a laminate 354 comprising the resistive heating layer 340 and the support layer 350. In embodiments, the laminate 354 comprises the aerosol generating layer 330. The aerosol generating layer 330 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 aerosol generating layer 330 comprises an aerosolgenerating film. In embodiments, the aerosol generating layer 330 comprises a plurality of aerosol-generating films. In embodiments, the aerosol-generating film comprises a plurality of aerosol-generating film regions. Such plurality of aerosol-generating films and/or plurality of aerosol-generating film regions may have different properties, for example at least one of different compositions, thicknesses, density, active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

One or more of the aerosol generating layer 330, resistive heating layer 340 and the support layer 350 may comprise a further layer. For example, the support layer 350 may comprise a backing layer or an intermediate layer. The support layer 350 in embodiments is omitted. Figure 8 shows one of the resistive heating elements 342. The resistive heating layer 340 comprises a plurality of resistive heating elements 342. In embodiments, the resistive heating layer 340 comprises a single resistive heating element 342.

The plurality of heating elements 342 may be formed in an array 344 as shown in Figure 9. Other configurations are envisaged. The resistive heating element 342 comprises a resistive heating path. The resistive heating path is formed by an electrically conducting path. The resistive heating path is non-straight. The resistive heating path is convoluted. The configuration of the resistive heating path may vary. The electrical resistance of the heating element 342 may be dependent on the nature of the resistive heating path in the conductive layer, for example the length, width, thickness and arrangement of the path.

The resistive heating element 342 extends between a first type of electrical contact 360 and a second type of electrical contact 365. The first type of electrical contact 360 is configured to provide a positive contact and the second type of electrical contact 365 is configured to provide a negative contact. Electrical current flows between the first type of electrical contact 360 and the second type of electrical contact 365 through the path. The contact arrangement may be reversed. The first and second types of electrical contacts 360, 365 are heater electrical contacts 322. The first and second types of electrical contacts 360, 365 form at least part of the article electrical contact configuration 320.

The meandering or serpentine nature of the path of the resistive heating element 342 is such that the electrical resistance of the path is increased when compared with a straight path between the first and second type of electrical contacts. The resistive heating layer 340 may comprise a first type of electrical track 361 extending from the resistive heating element 342. The first type of electrical track 361 comprises the first type of electrical contact 360. The electrical contact 360 of the first type is configured to electrically connect with the device electrical connector 230. The first type of electrical contact 360 comprises a first type of exposed contact region 362. The first type of exposed contact region 362 is exposed on the article for direct connection with the device electrical connector 230.

The resistive heating layer 340 may comprise a second type of electrical track 366 extending from the resistive heating element 342. The second type of electrical track 366 comprises the second type of electrical contact 365. The electrical contact 365 of the second type is configured to electrically connect with the device electrical connector 230.

The second type of electrical contact 365 comprises a second type of exposed contact region 367. The second type of exposed contact region 367 is exposed on the article 300 for direct connection with the device electrical connector 230.

As discussed in detail below, the conducting path of the resistive heating element 342 in embodiments is created by defining at least one electrical barrier 346 in the resistive heating layer 340. In embodiments, the electrical barrier 346 is formed by cutting electrical barrier 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 340. In embodiments, the electrically conductive element 342 is preformed to define the or each resistive heating element 342 and then applied to the support 350. In embodiments, the resistive heating layer 340 is applied to the support 350, and the or each resistive heating element 342 then defined in the resistive heating layer 340. The or each restive heating element 342 defining the resistive heating layer 340 may be a printed heater.

The at least one electrical barrier 346 defines the first and second types of electrical track 361 , 366.

In some embodiments, the tracks of the or each resistive heating element 342 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 or each resistive heating element 342 may have overall dimensions of the order of 10mm x 10mm. Other dimensions are possible in other example embodiments. By forming the or each resistive heating element 342 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.

As shown in Figure 9, the resistive heating layer 340 may be formed into a plurality of resistive heating elements, indicated generally by the reference numerals 342a, 342b, 242c, 342d and 342e. Each of the resistive heating elements 342a-342e extends from a respective one of the first type of electrical contact, indicated generally by the reference numerals 360a, 360b, 360c, 360d and 360e to a single second type of electrical contact 365. The number of electrical contacts may vary. As such, each resistive heating element 342a-342e extends between a discrete first type of electrical contact and a common second type of electrical contact.

Each of the resistive heating element 342a-342e provides an electrically conductive path for resistive heating of a portion of the aerosol generating material 302 to generate an aerosol at the respective portion of the aerosol generator 304. The separate first type 360a-360e of electrical contacts enable an electric current to be individually provided to each of the plurality of resistive heating elements 342a- 342e. The heating of different zones of the aerosol generating layer 330 can be controlled. For example, an aerosol generator may be provided with five aerosol generating zones. The resistive heating layer 340 allows each of those zones to be activated separately. Accordingly, for example, five puffs of aerosol may be generated from a single consumable incorporating a single aerosol generator 304, and ten puffs of aerosol may be generated from a single consumable incorporating two aerosol generators 304. In the example resistive heating layer 340, the plurality of first type of electrical contacts 360a-360e, for example a positive electrical connection, are provided and a single second type of electrical contact 365, for example a negative electrical connection is provided. This is not essential to all implementations. For example, multiple contacts of the second type could be provided. In embodiments each resistive heating element 342a-342e comprises a corresponding one of the first type of electrical contact 360 and a corresponding one of the second type of electrical contact 365.

In the shown embodiment of Figure 9 of the resistive heating layer 340, the first type of electrical contacts 360a-360e are arranged on a first edge 363 of the resistive heating layer 340 and the second type of electrical contact 365 is arranged on a second edge 368 of the resistive heating layer 340. This may allow for convenient connection of electrical power, but, of course, many other configurations are possible, some of which are discussed further below.

Figure 10 is a flow chart showing part of a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 400, in accordance with an example embodiment.

The method or algorithm 400 starts at operation 402, where a resistive heating layer is formed into one or more heating elements (e.g. a plurality of heating elements), wherein each resistive heating element extends from an electrical contact of a first type to an electrical contact of a second type. In use, the or each heating element may be used to provide an electrically conductive path for resistive heating of a portion of an aerosol generating material to generate an aerosol. The formation of the or each resistive heating element may occur prior to or post application of the resistive heating layer on a support, where a support is present. The resistive heating layer may be adhered to the support, or mounted or formed on the support in a different configuration. At operation 404, the formed resistive heating layer is placed in contact with the aerosol generating layer, wherein said aerosol generating layer incorporates aerosol generating material. Algorithm 400 may be used to produce the aerosol generator 304 described above. Figure 11 shows the aerosol generator 304 being formed in accordance with an embodiment. The aerosol generating material 302 is formed on the resistive heating layer 340 by depositing aerosol generating material, for example by spraying, painting, dispensing or in some other way. The aerosol generating layer 330 is disposed on resistive heating layer 340 as indicated by the arrow 406, in an example implementation of the operation 404.

Figure 12 shows the resistive heating layer 340 being formed in accordance with an example embodiment. The resistive heating layer 340 is in the process of being cut using a laser cutter 408. The cutting of the resistive heating layer 340 can be used to form the paths of the heating elements described herein. The use of the laser cutter 408 (or some other cutting process) is not the only method by which the resistive heating layer 340 described herein may be generated. Some example methods are described below.

Figure 13 is a flow chart showing part of a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 410. The method or algorithm 410 starts at operation 412, where the resistive heating layer is provided. At operation 414, one or more of the resistive heating elements are formed in the resistive heating layer by chemically etching the resistive heating layer. The operations 412 and 414 are an example implementation of the operation 402 of the method 400 described above. The aerosol generating material is then disposed on the resistive heating layer, thereby implementing the operation 404 described above.

Figure 14 is a flow chart showing part of a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 418. The method or algorithm 418 starts at operation 420, where one or more heating elements are formed, at least in part, by printing a resistive heating layer. The operation 420 is therefore an example implementation of the operation 402 of the algorithm 400 described above. The aerosol generating material is then disposed on the resistive heating layer, thereby implementing the operation 404 described above.

The cutting, etching and printing methods described above are provided by way of example; other additional or 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 a resistive heating layer, and then assembled/bonded onto a support. Yet other techniques could be used, such as die cutting. 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.

Figure 15 is a flow chart showing method of operation or an algorithm, indicated generally by the reference numeral 424, in accordance with an example embodiment. The method or algorithm 424 may, for example, be implemented using any of the aerosol generators described herein. The method or algorithm 424 is initiated when an instruction to activate heating is received in an instance of operation 426. In response to the instruction to activate heating, a determination is made (in operation 428) regarding whether a heating element is available. As discussed above, a plurality of heating elements may be provided. The operation 428 may involve determination which of the heating elements have been used and/or the corresponding available aerosol generating material used up.

If a heating element is available, the algorithm moves to operation 430, 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 430 is complete, the algorithm terminates at operation 432. If, at operation 428, a determination is made that no heating elements are available, for example because all heating elements have been used, then the algorithm terminates at operation 432. This may mean that a consumable part being used to implement the algorithm 424 needs to be replaced.

Figure 16 shows the resistive heating layer 340 being formed in accordance with an embodiment. The resistive heating layer 340 is being cut using the laser cutter 408, although other methods could be used, such as chemical etching or printing, as discussed above. The cutting of the electrically conductive layer 340 forms the heating elements as described herein.

In the embodiment of Figure 16, the paths cut are linear paths, extending along the length of the electrically conductive layer 120.

Figure 17 shows another embodiment of the resistive heating layer 340. The resistive heating layer 340 may be formed using the laser cutter 408 described above, or some similar device or another method. The resistive heating layer 340 comprises a plurality of resistive heating elements 342, each resistive heating element 342 being a linear heating element comprising a conducting path extending along a length of the resistive heating layer 340. Each resistive heating element 342 extends from one of the first type of electrical contact 360, for example a positive electrical connection to one of the second type of electrical contact 365, for example a negative electrical contact. In such an embodiment, both types of electrical contact are provided at the same end of the resistive heating layer 340 and are provided next to each other. In such an arrangement that there is free from a common second type of electrical contact as is some other embodiments; instead, each heating element has separate first and second types of electrical contacts.

Figure 18 shows another embodiment of the resistive heating layer 340. The resistive heating layer 340 may be formed using the laser cutter 408 described above, or some similar device or another method. The resistive heating layer 340 comprises a plurality of heating elements 342, each heater element 342 being a linear heating element comprising a conducting path extending along a length of the resistive heating layer 340. Each resistive heating element 342 extends from one of the first type of electrical contact 360, for example a positive electrical connection to the second type of electrical contact 365, for example a negative electrical contact. In such an embodiment, the different types of electrical connection are provided at the opposite ends of the resistive heating layer 340 and a common second type of electrical contact is provided. Although a linear path is provided, an increase in the electrical resistance may be provided by means of providing a crenelated path, acting as a convoluted path. Note that the paths of any other embodiments described herein could also be crenelated.

Figure 19 shows the distal end of the article 300. As shown, the body 324 comprises a plurality of body layers 325. The body layers 325 are arranged in a stack of body layers 325. The body layers 325 form a laminate. The body layers 325 in embodiments are card layers. Other suitable materials may be used. The body layers 325 are configured to define features of the article 300. At least one body layer in embodiments comprises a gap defining the air inlet 315. The gap defines the opening 314.

The aerosol generator 304 comprises the resistive heating layer 340. The resistive heating layer 340 comprises the resistive heating elements 342, the first type of electrical contacts 360, for example providing positive electrical connections to each of a plurality of heating elements 342 and a single second type of electrical contact 365, for example providing a common negative electrical connection to the plurality of heating elements 342. The first and second types of electrical contacts 360, 365, namely the heater contacts 322, together form at least part of the article electrical contact configuration 320 of the aerosol generator 304. The resistive heating elements 342 are on an inner side of the resistive heating layer 340. The inner side defines the first side 306 of the aerosol generator 304 as shown in Figure 3. The heater contacts 322 are on the second side 307 of the resistive heating layer 340. The second side 307 defines an outer side of the aerosol generator 304. The heater contacts 322 are exposed so that they are able to be brought into contact with the device electrical connector 230. The heater contacts 322 are on an opposing side of the resistive heating layer 340 to the resistive heating elements 342. Other configurations are envisaged.

The support layer 350 is between an inner portion of the resistive heating layer 340 and an outer portion of the resistive heating layer 340.

A fold 370 is formed in the resistive heating layer 340. The fold 370 defines the heater contacts 322. The fold 370 as shown in Figures 2 to 4 and 19 extends perpendicular to the longitudinal axis of the aerosol generator 304. The fold 370 defines a flap 372. The heater contacts 322 are on the flap 372. The flap defines a contact panel. The remaining part of the blank defines a main panel.

In embodiments with the support layer 350, the support layer 350 in embodiments is folded. The substrate 352 is folded at the fold 370. In embodiments, the support layer 350 ends at the fold. In embodiments, the fold 370 extends parallel to the longitudinal axis of the aerosol generator 304. The folded portion of resistive heating layer 340 is affixed in the folded position.

This folded portion in embodiments is adhered, for example by bonding. Other fixing means are anticipated.

The fold 370 defines the first type of exposed contact region 362. The fold 370 defines the second type of exposed contact region 367. The electrical tracks 361, 366 electrically communicate across the fold 370. The heater contacts 322 of the first type of electrical track 361 and the second type of electrical track 366 are defined on the second side of the resistive heating layer 340. Portions of the first type of electrical track 361 and the second type of electrical track 366 extend on the first side of the resistive heating layer 340. In embodiments the resistive heating elements extend from the fold 370. Other configurations are anticipated.

The device 200 comprises a plurality of connector electrical contacts 232 of the electrical connector 230. The configuration of the device connector 230 is dependent on the configuration of the heater contacts 322 of the aerosol generator 304. In embodiments, such as the aerosol generator as shown in Figure 19, the aerosol generator 300 comprises a plurality of heater contacts 322 including a plurality of the first type of heater contact 360 and one of the second type of heater contact 365. The article 300 comprises another set of heater contacts 322 on the opposing side of the article 300 corresponding to the second aerosol generator 304. Figure 20 shows a device connector 230 of the aerosol provision device 200 used in some embodiments. The connector 230 has separate connector electrical contacts 232 for connection with the heater contacts 322.

Figure 21 schematically shows the aerosol provision system 100. The system 100 comprises the article 300 and aerosol provision device 200, both shown in block diagram. The device 200 comprises first and second connectors 230a and 230b.

The connectors 230a and 230b enable the aerosol provision device 200 to provide regulated or controlled electrical voltages and/or currents to the various first and second type of heater contacts 360, 365 of the aerosol generator 304 when the article 300 is inserted into the aerosol provision device 200. The aerosol provision device 200 may comprise a connector arrangement configured to provide electrical power to the connectors 230a, 230b. The aerosol provision device 200 may, for example, operate the method as described above.

Figure 22 is a flow chart showing a method of forming an aerosol generator 304 or an algorithm, indicated generally by the reference numeral 440, in accordance with an example embodiment.

The method or algorithm 440 starts at operation 442, where a resistive heating layer is formed into at least one resistive heating element, the or each heating element providing an electrically conductive path for resistive heating of at least a portion of an aerosolisable material to generate an aerosol. Example heating elements that may be formed in the operation 442 are described elsewhere in this document.

At operation 442, an aerosol generating material is applied and/or formed on the resistive heating layer.

The operations 442 and 444 of the method or algorithm 440 are similar to (and may be identical to) the operations 402 and 404 of the method or algorithm 400 described above.

In operation 446 at least one first type of electrical contact is provided on the resistive heating layer. The method of formation may be any of the methods described above. In operation 448 at least one second type of electrical contact is provided on the resistive heating layer. The method of formation may be any of the methods described above.

In embodiments, the first and second types of electrical contact are formed along or proximal a single edge of the resistive heating layer. In embodiments, the first and second types of electrical contact are formed along or proximal to different edges of the resistive heating layer.

In embodiments, the first types of electrical contact (e.g. positive connection(s)) are provided along a first edge of the resistive heating layer. In embodiments, the second types of electrical contact (e.g. negative electrical connection(s)) are provided along a second edge of the resistive heating layer. The operations 446 and 448 could be performed in a different order, or at the same time. Moreover, the operations 446 and 448 could be performed together with the operation 442.

At operation 450, the resistive heating layer is folded. In embodiments, the support layer is folded together with the resistive heating layer. In embodiments, the resistive heating layer is folded such that electrical contacts of the first and second type are provided adjacent to one another, as discussed in detail below.

Figures 23 to 25 show an embodiment of the aerosol generator 304 being formed in accordance with the algorithm 440.

Figure 23 shows another embodiment of the aerosol generator 304 being formed. The resistive heating layer 340 (i.e. the heating arrangement 312 of the aerosol generator 304, and thus the article 300) is being cut using a laser cutter 408. The prefolded configuration defines a blank for forming the aerosol generator 304. The blank in embodiments defines fold lines along which folds are made during formation of the aerosol generator. The aerosol generator 304 blank comprises the resistive heating layer 340 and the support layer 350. The resistive heating layer 340 and the support layer 350 define panels defined by the fold lines.

As shown in Figure 23, the resistive heating layer 340 is formed into a plurality of heating elements , although the number may differ and may be one. A plurality of the first type of the electrical contact 360 (e.g. positive electrical contact) are provided along the first edge of the electrically conductive layer (one contact for each heating element is shown). A single second type of electrical contact 365 is provided along the second edge of the resistive heating layer 340. In embodiments the contacts are spaced from the edges. As discussed above, each heating element of the plurality extends from an electrical contact of the first type to an electrical contact of the second type. The cutting of the resistive heating layer 340 by the laser cutter 408 forms the paths of the or each heating element 342. As discussed above, laser formation or some other cutting process is not the only method by which the resistive heating layer 340 described above may be generated. Some example alternative methods include chemical etching and printing.

As indicated in Figure 24, the aerosol generating layer 200 is provided on the resistive heating layer 340. The blank is then folded, as indicated by the arrows in Figure 24. In this embodiment, the folds are formed parallel to a longitudinal direction of the aerosol generator 304. Two folds are formed. A first panel 375 is defined comprising the heating elements 342. A second panel 376 is formed comprising the plurality of the first type of the electrical contact 360. A third panel 377 is formed comprising the second type of electrical contact 365. The aerosol generating layer 330 is on the first panel 375. Figure 25 shows the folded aerosol generator 304.

Figure 26 shows the folded aerosol generator 304 in plan view. The article 300 comprising the folded aerosol generator 304 may be suitable for use with the aerosol provision device discussed below in relation to Figures 28 to 41. The electrical contacts of the first type 360a, 360b, 360c, 360d, 360e, and the electrical contact of the second type 365 can be seen. Both the electrical contacts 360, 365 are heater (or article) electrical contacts 322 as described above. Figure 27 shows the folded aerosol generator 304 with a wrap 501 which surrounds the folded aerosol generator 304, forming the article 300. The wrap 501 defines a plurality of first holes 502a, 502b, 502c, 502e, 502d, which align with the electrical contacts of the first type 360a, 360b, 360c, 360d, 360e, and a second hole 504 which aligns with the electrical contact of the second type 365 such that a plurality of electrical contacts 322 are left exposed.

It will be understood that both sides of the article 300 may comprise an arrangement of heater electrical contacts 322 as shown in Figure 27.

Figure 28 and 29 show a perspective view of an aerosol provision device 200 in accordance with an embodiment of the present invention. Any of the features of the aerosol provision device, aerosol provision system and article set out in the embodiments above may be applied to the aerosol provision device 200 discussed below. As shown in Figure 28, the aerosol provision device 200 comprises a first housing part 506a, a first sealing member 508a, a first electrical component 510a, which may comprise a first printed circuit board (PCB) 510a, and a plurality of electrical contact elements 512. The first sealing member 508a is sandwiched between the first housing part 506a, and the first PCB 510a. Whilst in the embodiment shown the first electrical component 510a is in the form of a PCB 510a, it will be appreciated that any other electrical component may be present. The aerosol provision device 200 may further comprise a second housing part

506b, along with a second sealing member 508b, and a second electrical component 510b, which may comprise a second printed circuit board (PCB) 510b. The second sealing member 508b is sandwiched between the second housing part 508b, and the second PCB 510b. Again, whilst a PCB 510b is shown, any other suitable second electrical component may be present.

In some embodiments, the first and second housing parts 506a, 506b both have approximately rectangular shapes, and are substantially planar (i.e. their length and width are notably larger than their depth or their dimensions in their main plane are notably larger than their dimensions in any other plane). This main plane of each housing part 506a, 506b, is referred to herein as the plane of that housing part. The first and second PCBs 510a, 510b, and the first and second sealing members 508a, 508b also have approximately rectangular shapes, and are also planar and, when assembled, the planes of the housing parts, sealing members, and PCBs are all parallel. Whilst components having a generally rectangular shape are discussed and shown in the Figures, it will be appreciated that the various components of the device may have any suitable shape and configuration.

The first and second housing parts 506a, 506b may be formed of an injection moulded polymer. The first and second sealing members 508a, 508b may be formed as sheets of silicone, Thermoplastic polyurethane (TPU), or Thermoplastic elastomer (TPE), or any other material that is capable providing a suitable seal. In some embodiments the first and second sealing members 508a, 508b may be overmoulded onto the first and second housing parts 506a, 506b.

The housing 204 of the aerosol provision device 200 can be seen in Figure 29.

The housing 204, as depicted, may be formed as a sleeve which slides over the internal components of the aerosol provision device 200. Of course, the housing 204 may take any other suitable form, e.g. in the form of a wrap which is wrapped around the internal components of the aerosol provision device 200 before being secured in place.

Figures 30 shows the second housing part 506b and the PCB 510b in isolation from the other components of the device 200. Figure 31 show the first housing part 506a separated from the second housing part 506b. At least one, e.g. both, of the first and second housing parts 506a, 506b may respectively define first and second recesses 507a, 507b such that when the first and second housing parts 506a, 506b are brought together during assembly of the aerosol provision device 200, the housing parts 506a, 506b, define a cavity (or chamber) 206 which is configured to receive, during use, the article 300. The cavity 206 may be considered to be an article receiving portion 206.

Both the first and second housing parts 506a, 506b may comprise a plurality of depressions 522, which may be formed within the first and second recesses 507a, 507b, which are each configured to partially receive an electrical contact element 512. The depressions 522 may be formed during the manufacture of the first and second housing parts 506a, 506b. As discussed above, the article 300 shown in Figure 27 is suitable for use with the presently discussed aerosol provision device 200. It can be seen when looking at both Figure 27 and Figure 31 together that the electrical contact elements 512 and heater electrical contacts 322 are correspondingly arranged such that when the article 300 is correctly inserted into the cavity 206, each electrical contact element 512 will align with a first hole 502a-e, or a second hole 504 in the wrap 501 such that the plurality of electrical contact elements 512 each make contact with a heater electrical contact 322.

On the opposite side of the first and second housing part 506a, 506b (i.e. the opposite side of the plane of the housing part) to the first and second recesses 507a, 507b, one or both of the first and second housing parts 506a, 506b may define a component receiving portion. In some embodiments, the first housing part 506a defines a first component receiving portion 511a, and the second housing part 506b defines a second component receiving portion 511b. The component receiving portions are discussed in more detail below with respect to Figure 39.

Figure 32 shows a perspective view of the first housing part 506a, specifically the side with the recess 507a therein, and Figure 33 shows a focussed perspective view at one end of the first housing part 506a. As can be seen from Figures 32 and 33, the first housing part 506a may further define a recess 513 which is configured to partially receive a further component, e.g. a battery 515, and a recess 517 which is configured to partially receive another component, e.g. an air inlet assembly 519 which forms part of an air-flow path from the outside of the device 200 into the cavity 206.

Figure 34 shows the first housing part 506a, first sealing member 508a, first PCB 510a, and electrical contact elements 512 in exploded view. The first housing part 506a defines a plurality of apertures 541 extending through the body of the first housing part 506a from the recess 507a to the component receiving portion 511a. In use, an article 300 will be received within the cavity 206 which is at least partially defined by the recess 507a. Aerosol generated by the article 300 may escape the article 300 and pass into the cavity 206. It may, therefore, be advantageous to seal the cavity 206 from the first PCB 510a to prevent the aerosol, which may contain moisture, from interfering with the electronics of the device. The sealing member 508a, which may be sandwiched between the first housing part 506a, and the first PCB 510a, may act to seal the apertures 541 such that aerosol cannot pass from the cavity 206, through the apertures 541 , and into the component receiving portion 511a. Whilst a single sealing member 508a is shown, the sealing member may instead comprise a plurality of sealing members, each sealing one or more of the apertures 541.

Figure 34 also shows a fastening member, which in the illustrated embodiment is in the form of a threaded screw 514. Through holes 516, 518, 520 configured to receive the screw 514 may be defined in each of the first housing part 506a, first sealing member 508a, and first PCB 510a respectively. In the illustrated embodiment, the head of the screw 514 is adjacent the first PCB 510a, and the tip of the screw is adjacent the first housing part 506a. Only the hole 520 in the first housing part 506a is threaded. In other embodiments, the screw 514 may be self-tapping. Whilst a threaded screw 514 is shown, any other suitable retention means may be used to hold the components, e.g. the first housing part 506a, the first sealing member 508a, and the first PCB 510a, of the device 200 together.

The first housing part 506a may comprise retention elements 521 which protrude from first housing part 506a, e.g. in a direction perpendicular to the plane of the first housing part 506a around the perimeter of the component receiving portion 511a. The retention elements 522 may be configured, e.g. dimensioned and/or arranged, to retain the first sealing member 508a, and first PCB 510a in correct alignment with the first housing part 506a.

The first sealing member 508a, and the first PCB 510a may also define holes 522 and 524 respectively. The first housing part 506a may also comprise fixture pins 526 (visible in Figure 35) which protrude from the from first housing part 506a, e.g. in a direction perpendicular to the plane of the first housing part 506a. In the illustrated embodiment, four fixture pins 526 are provided, one adjacent each corner of the component receiving portion 511a. The fixture pins 526 may extend into the holes 522, 524 on the sealing member 508a and first PCB 510a, thereby ensuring alignment therebetween.

Figure 35 shows a close-up cut-away view of a portion of the first housing part 506a. Visible in Figure 35 is a fixture pin 526 protruding through holes 522 and 524. The fixture pin 526 may have a first diameter at its base 528 (where the fixture pin joins the first housing part 506a) and a second, smaller diameter at its tip 530. A step 532 from the first diameter to the second diameter may be present part way up the fixture pin 526. The hole 522 in the first sealing member 508a may have a diameter which is equal to (or marginally greater than) the first diameter, and the hole 524 in the first PCB 510a has a diameter which is equal to (or marginally greater than) the second diameter. In this way, the first PCB 510a rests on the step 532. This may improve the stability and/or accuracy of positioning of the PCB 510a within the component receiving portion 511a.

One of the previously discussed depressions 522 can also be seen in Figure 35. The depression 522 may comprise a pedestal 535 protruding from the base of the depression 522, and configured to support an electrical contact element 512. The pedestal 535 defines a blind hole 536.

Figure 36 shows a close-up view of one of electrical contact elements 512 previously discussed and shown in position in Figure 35. The electrical contact element 512 is made from an electrically conductive material such as an electrically conductive metal. The electrical contact element 512 may comprise a plurality of portions, e.g. three portions including: a component contacting portion 538, an article contacting portion 540, and a mid-portion 542 which connects the component contacting portion 538 to the article contacting portion 540. The mid-portion 542 defines a through-hole 544 which is configured to align with the blind hole 536 in the pedestal 534 when appropriately aligned therewith. The function of the blind hole 536 and through hole 544 is explained later in relation to Figures 37-39.

It can be seen from Figure 35 that the first housing part 506a defines an aperture 541 through which the component contacting portion 538 passes. The first PCB 510a also comprises a through-hole 543 which is aligned with the aperture 541 and which is configured to receive the component contacting portion 538. However, no through-hole is provided in the first sealing member 508a. Rather, with reference to Figure 36, the component contacting portion 538 of the electrical contact element 512 comprises a pointed tip 539 which is configured to pierce the first sealing member 508a during assembly of the device 200. Having the electrical contact elements 512 pierce the sealing member during assembly of the device 200 (as opposed to providing prefabricated holes in the sealing member) is advantageous since the hole created by the electrical contact element 512 will be exactly the correct size, and so there will be no (or minimal) leakage of aerosol from the cavity 206 to the component receiving portions 511a, 511b. Piercing the sealing member 508a in this manner may also ensure a reliable seal between the sealing member and the electrical contact element 512. The sealing member 508a may be made from a resilient deformable material which, when pierced, seals around the electrical contact element. In embodiments, the sealing members 508a, 508b are formed of a flexible material such as silicone, in such embodiments, a tighter seal between the sealing member 508a, 508b, and the electrical contact elements 512 may be achieved at the location of the piercing.

It will be understood that the above described arrangement may be the same for each of the depressions 522 and electrical contact elements 512.

A method of manufacturing part of the aerosol provision device 200, specifically part of the aerosol provision device 200 described above with reference to Figures 28- 36, will now be explained with reference to Figures 37 to 39.

Figure 37 shows an assembly block 550 which may be used in the method of manufacturing. The assembly block may have an approximately cuboidal shape and has a top face 552 which may have a complementary shape to that of the first recess 507a of the first housing part 506a, such that the first housing part 506a fits snugly onto the top face 552. On the top face 552, the assembly block 550 comprises a plurality (e.g. six) of alignment structures 554. The alignment structures 554 are arranged on the top face 552 so as to align with the depressions 522 and apertures 541 in the first housing part 506a (and thus also the through-holes 543 in the first PCB 510a). The number of alignment structures may thus depend on the number of depressions 522, and thus the number of electrical contact elements 512 on the device.

Each alignment structure 554 is configured to retain an electrical contact element 512 and comprises a pedestal 556 configured to support the mid-portion 542, and a recess 557 configured to partially receive the article contacting portion 540. On the pedestal 556, a fixture pin 558, e.g. a cylindrical fixture pin 558, is provided which protrudes from the top face 552 and is configured to pass through the hole 544 in the mid-portion 542 of the electrical contact element 512, and be received in the blind hole 536 in the depression pedestal 535 of the first housing part 506a. A method of manufacture 600 in accordance with an embodiment of the present invention is illustrated in the flowchart of Figure 38 which will be explained below with reference to Figures 39 and 40. At step 601 , the electrical contact elements 512 may be placed into the alignment structures on the top face 552 of the assembly block 550 such that, for each electrical contact element 512 and alignment structure 554 pair, the midportion 542 of the contact element 512 is supported on the pedestal 556, the article contacting portion 540 is partially received within the recess 557, and the fixture pin 558 protrudes through the hole 544. Step 601 of Figure 39 shows the electrical contact elements 512 in place on the assembly block 550. After step 601 , the method has two alternatives, represented by the two adjacent step flows 602-603-604, and 612-613-614.

It is the first alternative which is illustrated in Figure 39 and so this alternative will be described first.

At step 602, the assembly block 550 (with the electrical contact elements 512 in place) is brought together with the first housing part 506a such that the component contacting portions 538 of the electrical contact element 512 protrude through the apertures 541 as shown in step 602 of Figure 39, and in close-up in Figure 40.

At step 603, the first sealing member 508a is pressed into the component receiving portion 511a. Since the component contacting portions 538 each have pointed (e.g. sharp) tips 539 which are protruding from the apertures 541 , the tips 539 pierce and protrude through the sealing member 508a. The sealing member 508a, e.g. due to it being made from a flexible, e.g. deformable, material, may nonetheless seal the apertures 541. At step 603 of Figure 39, the component contacting portions 538 can still be seen protruding from the sealing member 508a. It can further be seen from Figure 39 that, whilst pressing the sealing member 508a into the component receiving portion 511a, alignment is maintained via the retention elements 521 , and the fixture pins 526 and holes 522.

At step 604, the electrical component 510a (PCB) is pressed into the component receiving portion 511a such that the component contacting portions 538 of the electrical contact elements 512 are received in the holes 543 in the component. It can be seen from Figure 39 that, whilst pressing the electrical component 510a into the component receiving portion 511a, alignment is maintained via the retention elements 521 , and the fixture pins 526 and holes 524. The first component receiving portion 511a may be shaped to receive both the first electrical component (PCB) 510a, and the first sealing member 508a such that the component receiving portion 511a may be considered to also define a sealing member receiving portion. The alternative method illustrated by the second flow of the flow chart in Figure

38 is essentially a reversal of the steps 602-604. First, at step 612, the sealing member 508a is pressed into the component receiving portion 511a, sealing the apertures 541. Then, at step 613, the electrical component 510a is pressed into the component receiving portion 511a. Then, at step 614, the assembly block 550 (with the electrical contact elements 512 in place) is brought together with the combined first housing part 506a, sealing member 508a and electrical component 510a such that the pointed tips 539 pierce the sealing member 508a and the component contacting portions 538 protrude through the apertures 541 and into the holes 543 in the component 410a.

The two alternative methods re-converge at step 605 where the electrical contact elements 512 (specifically the component contacting portions 538 are fixed to the electrical component. In embodiments, this fixing comprises soldering the electrical contact elements 512 to the PCB 410a. Of course, any other means for electrically connecting the component contacting portions 538 and corresponding electrical contacts on the electrical component 510a, e.g. mechanical connections, may be utilised. Finally, at step 606, the assembly block 550 may be removed. Whilst the method

600 described above utilises the assembly block 550 to assist in alignment of the electrical contact elements 512, it will be appreciated that this is not essential and the electrical contact elements 512 may be inserted into the first housing part 506a in any suitable manner. Having the electrical contact elements 512 pierce the sealing member during assembly of the device 200 (as opposed to providing pre-fabricated holes in the sealing member) is advantageous since the hole created by the electrical contact element 512 will be exactly the correct size, and so there will be no (or minimal) leakage of aerosol from the cavity 206 to the component receiving portions 511a, 511b. In embodiments, the sealing members 508a, 508b are formed of a flexible material such as silicone, in such embodiments, a tighter seal between the sealing member 508a, 508b, and the electrical contact elements 512 may be achieved at the location of the piercing.

The use of the assembly block 550 may help to increase the efficiency of the method of manufacturing by providing a means of quickly and accurately aligning the electrical contact elements 512 with the apertures 541, and then inserting the electrical contact elements 512 into the apertures 541.

Figure 41 shows a cross sectional view through an aerosol provision device 200 according to the described invention, with an article 300 inserted into the cavity 206. It can be seen that the electrical contact elements 512 are in electrical contact both with the first and second PCBs 410a, 410b, and with the electrical contacts 322 of the article 300. It will be understood that unless explicitly stated otherwise, the features of the second housing part 506b, second electrical component 510b, and second sealing member 508b may be the same as the features of the first housing part 506a, first electrical component 510a, and first sealing member 508a. Further, although the method of manufacture explained in relation to Figures 37-40 has been explained in relation to the first housing part 506a, first electrical component 510a, and first sealing member 508a, the method applies equally to the manufacture of the second housing part 506b, second electrical component 510b, and second sealing member 508b. 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 comprise, 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 nontobacco 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

Claims

1. An aerosol provision device comprising: a housing part which at least partially defines: a cavity shaped to receive, during use, an article which comprises: an aerosol generating material, a plurality of article electrical contacts providing an electrical connection to the article, and a heating arrangement comprising at least one resistive heating element; and a component receiving portion shaped to receive an electrical component of the aerosol provision device; wherein the housing part comprises one or more apertures extending through a body of the housing part from the cavity to the component receiving portion; wherein the aerosol provision device further comprises: one or more electrical contact elements arranged to extend through the one or more apertures so as to engage an electrical component arranged within the component receiving portion and to engage with respective ones of the article electrical contacts when an article is received within the cavity; and at least one sealing member arranged to seal the one or more apertures; wherein each of the one or more electrical contact elements comprise a pointed tip configured to pierce the sealing member during assembly of the aerosol provision device such that the one or more electrical contact elements protrude through the sealing member so as to make an electrical connection with the electrical component.

2. The aerosol provision device of claim 1, wherein the housing is formed from a polymeric material.

3. The aerosol provision device of claim 1 or claim 2, wherein the at least one sealing member comprises a plurality of sealing members, and wherein each sealing member seals one of the plurality of apertures.

4. The aerosol provision device of any one of the preceding claims, wherein the aerosol provision device further comprises an electrical component, comprising a plurality of component electrical contacts, arranged within the component receiving portion and wherein the plurality of electrical contact elements engage with corresponding ones of the component electrical contacts.

5. The aerosol provision device of claim 4, wherein the electrical component comprises a printed circuit board.

6. The aerosol provision device of claim 4 or claim 5, further comprising one or more fasteners configured to secure the electrical component against the at least one sealing member.

7. The aerosol provision device of any one of the preceding claims, wherein the at least one sealing member comprises a sheet of flexible material.

8. The aerosol provision device of any one of the preceding claims, wherein the housing is configured to retain a battery.

9. The aerosol provision device of any one of the preceding claims, wherein the aerosol provision device comprises a further housing part, and wherein the first and second housing parts together define the cavity.

10. The aerosol provision device of any one of the preceding claims, wherein the aerosol provision device comprises a cover, and wherein the cover and the housing part together define the component receiving portion.

11. The aerosol provision device of any one of the preceding claims, wherein the housing part further defines a sealing member receiving portion shaped to receive at least part of the at least one sealing member.

12. A method of manufacturing at least part of an aerosol provision device, the aerosol provision device comprising: a housing part which at least partially defines: a cavity shaped to receive, during use, an article which comprises: an aerosol generating material, a plurality of article electrical contacts providing an electrical connection to the article, and a heating arrangement comprising at least one resistive heating element; and a component receiving portion shaped to receive an electrical component of the aerosol provision device; wherein the housing part comprises one or more apertures extending through a body of the housing part from the cavity to the component receiving portion, the method of manufacture comprising: arranging one or more electrical contact elements, each having a pointed tip, to extend through the one or more apertures so as to engage an electrical component arranged within the component receiving portion and to engage with respective ones of the article electrical contacts when an article is received within the cavity; and then pressing at least one sealing member into a position in which the one or more apertures are sealed, and the pointed tips of the one or more electrical contact elements pierce the sealing member such that the one or more electrical contact elements protrude through the sealing member so as to make an electrical connection with electrical component; or the method of manufacture comprising: sealing the one or more apertures with at least one sealing member; and then inserting one or more electrical contact elements, each having a pointed tip, through the one or more apertures and piercing the sealing member with the pointed tips of the one or more electrical contact elements such that the one or more electrical contact elements protrude through the sealing member so as to make an electrical connection with electrical component.

13. The method of claim 12, wherein the method comprises placing the one or more electrical contact elements on an assembly block to align the one or more electrical contact elements with the one or more apertures before inserting the one or more electrical contact elements through the one or more apertures.

14. The method of claim 13, wherein the assembly block comprises one or more fixture pins which are configured to engage with the one or more electrical contact elements, and with the housing part.

15. The method of claim 14, wherein the one or more electrical contact elements each comprise a hole configured to receive the one or more fixture pins when the one or more first electrical contact elements are placed on the assembly block.

16. The method of claim 15, wherein the hole is a through hole extending through entire depth of the one or more electrical contact elements

17. The method of any of claims 14 to 16, wherein the housing part comprises one or more alignment holes configured to receive the one or more fixture pins when the one or more first electrical contact elements are inserted through the one or more apertures.

18. The method of claim 17, wherein the alignment hole is a blind hole.

19. The method of any one of claims 13 to 18, further comprising, arranging an electrical component within the component receiving portion, fixing the one or more electrical contact elements to the electrical component, and then removing the assembly block.

20. The method of any of claims 12 to 19, comprising soldering the one or more electrical contact elements to the electrical component.