Heater assembly

Abstract

A heater assembly (300) for use in an aerosol generation system (100) is provided. The heater assembly (300) includes a liquid aerosol-forming substrate storage component (302) and a heating element (304). The heating element (304) includes a first portion (306) and a second portion (308). The first portion (306) of the heating element (304) is embedded in the liquid aerosol-forming substrate storage component (302), and the second portion (308) of the heating element (304) is not embedded in the liquid aerosol-forming substrate storage component (302). An aerosol generation system (100) including the heater assembly (300) is also provided.

Description

Technical Field

[0001] The present disclosure relates to a heater assembly. In particular, the present disclosure relates to a heater assembly for use in an aerosol generation system. The present disclosure also relates to a method of assembling a heater assembly, a cartridge including the heater assembly, and an aerosol generation system including the heater assembly.

Background Art

[0002] In many known aerosol generation systems, a liquid aerosol forming substrate is heated and vaporized into a vapor. The vapor is cooled and condensed to form an aerosol. In some aerosol generation systems, such as an electrically heated smoking system, this aerosol is then inhaled by a user.

[0003] Typically, a liquid aerosol forming substrate includes several compounds that vaporize when heated. These compounds can have different boiling points. For example, a liquid aerosol forming substrate can include nicotine (which has a boiling point of about 247 degrees Celsius at atmospheric pressure) and glycerol (which has a boiling point of about 290 degrees Celsius at atmospheric pressure).

[0004] When a liquid aerosol forming substrate having compounds with different boiling points is heated, the compounds with lower boiling points can vaporize before the compounds with higher boiling points. Alternatively, or additionally, the compounds with lower boiling points can vaporize at a faster rate than the compounds with higher boiling points.

[0005] This may be undesirable because the interactions and combinations between different compounds may be limited. For example, a liquid aerosol-forming substrate may contain nicotine compounds and organic acid compounds, and these compounds have different boiling points. Both of these compounds may be vaporized. Nicotine in the liquid aerosol-forming substrate may form free base nicotine when vaporized. However, it may be preferable to generate the aerosol using a nicotine salt rather than free base nicotine. To form this nicotine salt, the free base nicotine may be protonated by a vaporized organic acid. However, this protonation may be limited if the organic acid does not vaporize until after the nicotine has vaporized, or vaporizes more slowly than is necessary to protonate a suitable proportion of free base nicotine.

[0006] Furthermore, the rapid vaporization of some compounds in the aerosol-forming substrate compared to others is undesirable, as it can alter the properties of the generated aerosol over time, for example, during the process of smoke extraction in an aerosol-generating system. This is because, when the heating element is activated and the temperature rises in the initial stages of smoke extraction, the liquid aerosol-forming substrate near the heating element may reach a first temperature at which the first compound with a lower boiling point vaporizes, while the second compound with a higher boiling point does not. Later in the smoke extraction process, the liquid aerosol-forming substrate near the heating element may reach a second temperature at which the second compound with a higher boiling point vaporizes. However, at this point, most of the first compound in the liquid aerosol-forming substrate near the heating element may have already vaporized. Therefore, the generated aerosol may contain a larger proportion of the first compound in the initial stages of smoke extraction, and the generated aerosol may contain a larger proportion of the second compound in the later stages of smoke extraction.

[0007] Alternatively, or additionally, the properties of the generated aerosol may change during some stages of vapor extraction. This can occur if the compounds of the liquid aerosol-forming substrate are not vaporized at an appropriate rate. For example, the liquid aerosol-forming substrate may contain X mass percent of a first compound and Y mass percent of a second compound. If the liquid aerosol-forming substrate is not vaporized to produce a vapor containing the first compound to the second compound in a mass ratio of X to Y, the composition of the liquid aerosol-forming substrate may change as the vapor is generated. This, in turn, can lead to a change in the properties of the aerosol generated by the liquid aerosol-forming substrate. [Overview of the project]

[0008] The object of the present invention is to control the vaporization of various compounds of a liquid aerosol-forming substrate, where these compounds have different boiling points.

[0009] According to aspects of this disclosure, a heater assembly is provided. The heater assembly may be suitable for use in an aerosol generating system. The heater assembly may include a liquid aerosol-forming substrate storage component. The heating element may include a first part. The heating element may include a second part. The first part of the heating element may be embedded in the liquid aerosol-forming substrate storage component. The second part of the heating element may not be embedded in the liquid aerosol-forming substrate storage component.

[0010] The heater assembly can provide the liquid aerosol-forming substrate storage component with a higher temperature region and a lower temperature region. Alternatively, or additionally, the heater assembly can provide the liquid aerosol-forming substrate storage component with a region where the temperature rises at a faster rate and a region where the temperature rises at a slower rate.

[0011] Advantageously, the heater assembly can improve control over the vaporization of different compounds of the liquid aerosol-forming substrate. The heater assembly can simultaneously vaporize liquid aerosol-forming substrate compounds having higher and lower boiling points at a desired rate. The heater assembly can vaporize liquid aerosol-forming substrate compounds having higher and lower boiling points in a more favorable ratio. The heater assembly can provide the generation of aerosols with a more desirable composition. The heater assembly can provide more consistent generation of aerosols with desirable properties.

[0012] The heating element may comprise a third and a fourth part. The third part of the heating element may be embedded in the liquid aerosol-forming substrate storage component. The fourth part does not need to be embedded in the liquid aerosol-forming substrate storage component.

[0013] Advantageously, this can generate more regions of higher temperatures and more regions of lower temperatures in the liquid aerosol-forming substrate storage component. Alternatively, or additionally, this can provide more regions of faster temperature increases and more regions of slower temperature increases in the liquid aerosol-forming substrate storage component. This can result in a liquid aerosol-forming substrate compound in which higher boiling points and lower boiling points vaporize simultaneously at desired rates.

[0014] The second part of the heating element may extend between the first and third parts. That is, in the second potion of the heating element, the first part of the heating element may be connected to the third part of the heating element. The third part may be connected to the first part only through the second part.

[0015] The third part of the heating element may extend between the second and fourth parts. That is, in the third potion of the heating element, the second part of the heating element may be connected to the fourth part of the heating element. The fourth part may be connected to the second part only through the third part.

[0016] The heating element, or one, two or more, or all of the first, second, third, and fourth parts, may include an electrical resistive material. The heater assembly may be configured to allow current to pass through the aforementioned parts or parts during use. This may cause the aforementioned parts or parts to resistively heat. Thus, the aforementioned parts or parts may be configured to resistively heat.

[0017] One, two or more, or all of the first, second, third, and fourth parts of the heating element may be formed from the same material.

[0018] One, two or more, or all of the first, second, third, and fourth parts of the heating element may have substantially the same electrical resistivity (measured in ohms). For example, the first and second parts may have the same electrical resistivity. Alternatively, or additionally, the third and fourth parts of the heating element may have the same electrical resistivity. As used herein, the term “substantially the same electrical resistivity” is used to mean within 20, 10, or 5 percent of a given electrical resistivity.

[0019] The heating element, or one, two or more, or all of the first, second, third, and fourth parts of the heating element, may include or be formed from any material having suitable electrical and mechanical properties, such as a suitable electrical resistance material. Suitable materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilide), carbon, graphite, metals, alloys, and composite materials made of ceramic and metallic materials. Such composite materials may include doped or undoped ceramics. A suitable example of a doped ceramic is doped silicon carbide. Suitable examples of metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable alloys include stainless steel, constantan, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel, iron, cobalt, stainless steel-based superalloys, Timetal®, iron-aluminum alloys, and iron-manganese-aluminum alloys. Timetal® is a registered trademark of Titanium Metals Corporation (1999 Broadway Suite 4300, Denver Colorado). In composite materials, the electrical resistive material may be embedded in, sealed in, or coated with an insulating material, depending on the required energy transfer dynamics and external physicochemical properties. The heating element may include a metallic, etched foil insulated between two layers of inert material. In that case, the inert material may include Kapton®, full-layer polyimide, or mica foil.Kapton® is a registered trademark of EIdu Pont de Nemours and Company (1007 Market Street, Wilmington, Delaware 19898, United States of America).

[0020] The third and fourth parts may be configured to be resistively heated. The third and fourth parts may include an electrical resistance material. The first and second parts may be configured to be resistively heated. The first and second parts may include an electrical resistance material.

[0021] The heating element, or one, two or more, or all of the first, second, third, and fourth parts, may include susceptor material. The heater assembly may be configured so that the aforementioned parts or parts are inductively heated during use.

[0022] For example, a heater assembly may be configured for use in an aerosol generating system that includes an inductor, such as an inductor coil. The inductor may be located within an aerosol generating device having a power supply. The device may be configured to engage with the heater assembly or a cartridge containing the heater assembly. Alternatively, the inductor may be located within a cartridge containing the heater assembly. The cartridge may be configured to engage with an aerosol generating device having a power supply.

[0023] The power supply may be configured to supply alternating current to an inductor in a cartridge or an inductor in a device, such that the inductor generates a fluctuating electromagnetic field.

[0024] Alternating current can have any suitable frequency. The alternating current can be a high-frequency alternating current. The term high-frequency alternating current may refer to frequencies between 100 kilohertz (kHz) and 30 megahertz (MHz). If the inductor is a tubular inductor coil, the alternating current can have frequencies between 500 kilohertz (kHz) and 30 megahertz (MHz). If the inductor is a flat inductor coil, the alternating current can have frequencies between 100 kilohertz (kHz) and 1 megahertz (MHz).

[0025] The heating element, or one, two or more, or all of the first, second, third, and fourth parts, may be located within or otherwise subjected to the electromagnetic field generated by the inductor. This may generate eddy currents and hysteresis losses within the susceptor material. This may heat the susceptor material. Therefore, the power supply and inductor may be configured to inductively heat one, two or more, or all of the first, second, third, and fourth parts.

[0026] The susceptor material may be any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate, or may include such material. Preferred susceptor materials may be heated to temperatures above 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. Preferred susceptor materials may include metal, or carbon, or both metal and carbon. Preferred susceptor materials may include ferromagnetic materials, such as ferrite iron, or ferromagnetic steel or stainless steel. Preferred susceptor elements may be one or more of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum, or may include such materials. Preferred susceptor materials may include or be formed from 400 series stainless steel, such as grade 410, or grade 420, or grade 430 stainless steel. Different materials dissipate different amounts of energy when placed in an electromagnetic field with similar values ​​of frequency and electric field strength. Thus, parameters of the susceptor material, such as the type and size of the material, may be modified to provide desirable power dissipation within a known electromagnetic field.

[0027] The third and fourth parts may be configured to be induction heated. The third and fourth parts may include a susceptor material. The first and second parts may be configured to be induction heated. The first and second parts may include a susceptor material.

[0028] Advantageously, in an aerosol generation system using induction heating, there is no need to form electrical contacts between the heater assembly and the aerosol generator. Further, the heating element may not need to be electrically joined to other components. This can eliminate the need for solder or other joining elements. A cartridge incorporating a heater assembly configured to be inductively heated can enable the manufacture of simple, inexpensive, and robust cartridges. Cartridges are typically disposable items that are manufactured in much larger quantities than the aerosol generators in which they operate. Therefore, reducing the cost of the cartridges can lead to significant cost savings for the manufacturer. Further, induction heating can provide improved energy conversion compared to resistive heating. This is because induction heating does not have power losses associated with electrical resistance in the connection between the resistive heating element and the power source.

[0029] The heating element can have a length, width, and thickness. The heating element may include a strip-shaped material. The strip may have a length, width, and thickness. The width may be perpendicular to the length. The thickness may be perpendicular to the length and width. The length may be greater than the width. The width may be greater than the thickness.

[0030] The cross-section, or cross-sectional area, of the heating element can vary. For example, the cross-section, or cross-sectional area, of the heating element can vary along the length of the heating element.

[0031] The heating element may extend between a first end and a second end. For example, the length of the heating element may extend between a first end and a second end. The heating element may have a first cross-sectional area at a first point between the first end and the second end. The heating element may have a second cross-sectional area at a second point between the first point and the second end. The heating element may have a third cross-sectional area at a third point between the second point and the second end. The first and third cross-sectional areas may each be larger or smaller than the second cross-sectional area. For example, the first and third cross-sectional areas may be at least 10, 20, 50, 100, 200, or 500 percent larger or at least 10, 20, 30, 40, 50, 60, 70, or 80 percent smaller than the second cross-sectional area. Thus, observing how the cross-sectional area of ​​the heating element changes from the first end to the second end, the cross-sectional area of ​​the heating element may decrease and then increase. Alternatively, or additionally, the cross-sectional area of ​​the heating element can be increased or decreased.

[0032] Changing the cross-section or cross-sectional area of ​​a heating element can result in different sections of the heating element reaching different temperatures simultaneously. For example, in a resistance heating element, sections of the heating element with a smaller cross-sectional area may have greater resistance and therefore may be resistively heated to higher temperatures.

[0033] Advantageously, this can generate regions of higher and lower temperatures. Alternatively, or additionally, this can provide regions in the liquid aerosol-forming substrate storage component where the temperature rises at a faster rate and regions where the temperature rises at a slower rate. As described above, this can result in a liquid aerosol-forming substrate compound in which higher and lower boiling points are vaporized simultaneously at the desired rates.

[0034] The minimum cross-sectional area along the length of the heating element may be at least 10 percent smaller than the maximum cross-sectional area along the length of the heating element. The minimum cross-sectional area along the length of the heating element may be at least 20, 40, 60, or 80 percent smaller than the maximum cross-sectional area along the length of the heating element.

[0035] The minimum cross-sectional area of ​​the first part of the heating element may be at least 10, 20, 40, 60, or 80 percent smaller than the maximum cross-sectional area of ​​the second or fourth part. Alternatively, or additionally, the minimum cross-sectional area of ​​the third part of the heating element may be at least 10, 20, 40, 60, or 80 percent smaller than the maximum cross-sectional area of ​​the second or fourth part.

[0036] The width or thickness of the heating element, or both, may vary along the length of the heating element.

[0037] The heating element may be woven into and out of the liquid aerosol-forming substrate storage component. The heating element may include strip-shaped material woven into and out of the liquid aerosol-forming substrate storage component. The heating element or strip may be woven into and out of the liquid aerosol-forming substrate storage component along its length. Therefore, when traced along the length of the heating element or strip, the heating element or strip may alternately include portions embedded in the liquid aerosol-forming substrate storage component, such as the first and third portions, and portions not embedded in the liquid aerosol-forming substrate storage component, such as the second and fourth portions.

[0038] Advantageously, heater assemblies, which include heating elements woven into and outside the liquid aerosol-forming substrate storage components, can sometimes be relatively easy to manufacture.

[0039] The heating element may include one or more of the following: curves, ridges, folds, and waves. The first part of the heating element may include one or more of the following: curves, ridges, folds, and waves. The second part of the heating element may include one or more of the following: curves, ridges, folds, and waves. The third part of the heating element may include one or more of the following: curves, ridges, folds, and waves. The fourth part of the heating element may include one or more of the following: curves, ridges, folds, and waves. The fifth part of the heating element may include one or more of the following: curves, ridges, folds, and waves.

[0040] Advantageously, curves, undulations, folds, and waveforms in a heating element can allow for greater control over the location of higher and lower temperature regions. Alternatively, or additionally, curves, undulations, folds, and waveforms in a heating element can allow for greater control over the temperature difference between higher and lower temperature regions. For example, if a higher temperature is desired in a given region of a liquid aerosol-forming substrate storage component, the heating element may include undulations or waveforms within this region. This can increase the volume or surface area of ​​the heating element within this region, and therefore increase the heat transferred from the heating element to this region.

[0041] The heating element may have a first end and a second end. The length of the heating element may extend from the first end to the second end. If the heating element does not extend directly from the first end to the second end, i.e., is linear, the heating element may be considered to include one or more of the following: curves, undulations, folds, and corrugations.

[0042] The curve may refer to a stepwise change in the direction of the heating element, for example, a stepwise change in the direction of the heating element between the first end and the second end. Therefore, the curve may form a circular arc or a "C" shape.

[0043] A fold may refer to a gradual change in the orientation of the heating element, for example, a gradual change in the orientation of the heating element between the first end and the second end. Thus, a fold may form two sides of a polygon, or a "V" shape.

[0044] The undulations may include multiple curves. For example, the undulations may refer to a stepwise change in the direction of the heating element in a first direction, followed by a stepwise change in the direction of another heating element, for example, in the opposite direction. Thus, the undulations may form a sine wave or an "S" shape.

[0045] The waveform may contain multiple folds. For example, the waveform may refer to a stepwise change in the direction of the heating element, followed by another stepwise change in the direction of the heating element. Thus, the waveform may form three sides in the shape of a rectangle, or an "M" shape, or an "N" shape.

[0046] Advantageously, a heating element having one or more of the following characteristics: curves, undulations, folds, and corrugations, can simplify the manufacture of a heater assembly having at least a portion of the heating element embedded in a liquid aerosol-forming substrate storage component and at least a portion not embedded in the liquid aerosol-forming substrate storage component. Furthermore, one or more of the curves, undulations, folds, and corrugations may enable the heating element to generate a higher temperature region. For example, a portion of the heating element embedded in a liquid aerosol-forming substrate storage component may have a strongly curved "S" shape. The region of the liquid aerosol-forming substrate storage component around this portion of the heating element may be heated to a higher temperature.

[0047] The heating element may include one or more irregular undulations and irregular waveforms along the length of the heating element. As used herein, the terms irregular undulations and irregular waveforms refer to undulations and waveforms that do not have a constant amplitude and frequency.

[0048] The amplitude of the undulation or waveform can be measured perpendicular to the length of the heating element. The amplitude of the undulation or waveform can also be measured in the direction of the thickness of the heating element. The amplitude may refer to half the difference in height between the peak or maximum value of the undulation or waveform and the trough or minimum value of the undulation or waveform.

[0049] The frequency of a wave or undulation refers to the number of repeating cycles per unit distance, for example, in the direction of the length of the heating element or in the direction between the first and second ends of the heating element. This type of frequency is often called the spatial frequency. For example, if a heating element contains a regular sine wave, the wave is considered a wave, and the frequency of those waves is 1 divided by the wavelength of the wave.

[0050] An example of regular fluctuations is a predictable sine wave with constant amplitude and frequency.

[0051] The frequency of the fluctuations or waveform of the heating element may vary along the length of the heating element.

[0052] The amplitude of the undulation or waveform of the heating element may vary along the length of the heating element.

[0053] Advantageously, by varying the amplitude, frequency, or both, greater control over the location of higher and lower temperature regions may be possible. Alternatively, or additionally, by varying the amplitude, frequency, or both, greater control over the temperature difference between higher and lower temperature regions may be possible.

[0054] The heater assembly may include a storage section for storing a liquid aerosol-forming substrate.

[0055] A liquid aerosol-forming substrate storage component may be configured to store or store a liquid aerosol-forming substrate.

[0056] The liquid aerosol-forming substrate storage component may be in fluid communication with the storage section. In this case, during use, sections of the heating element further away from the storage section of the liquid aerosol-forming substrate, or regions within the liquid aerosol-forming substrate storage component around these sections of the heating element, may reach higher temperatures than sections or regions closer to the storage section of the liquid aerosol-forming substrate. This is because, for sections of the heating element closer to the storage section of the liquid aerosol-forming substrate, more heat may be transferred from the heating element to the storage section, or heat may be transferred more quickly.

[0057] Advantageously, the liquid aerosol-forming substrate storage component is in fluid communication with the storage unit, allowing the liquid aerosol-forming substrate to be vaporized, removed from the liquid aerosol-forming substrate storage component, and replenished quickly and automatically.

[0058] The liquid aerosol-forming substrate storage component may include, or may be, a material immersed in the liquid aerosol-forming substrate, or a material configured to be immersed in the liquid aerosol-forming substrate. The liquid aerosol-forming substrate storage component may have a fibrous structure or a spongy structure. The liquid aerosol-forming substrate storage component may include capillary material. The liquid aerosol-forming substrate storage component may include a bundle of capillaries. For example, the liquid aerosol-forming substrate storage component may include one or more of fibers, threads, and microtubules.

[0059] The liquid aerosol-forming substrate storage component may contain a sponge-like material or a foam-like material. The structure of the liquid aerosol-forming substrate storage component may form a plurality of small holes or tubes through which the liquid can be transported by capillary action.

[0060] Liquid aerosol-forming substrate storage components may include any suitable material or combination of materials. Suitable materials include, but are not limited to, sponge or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, foamable metal or plastic materials, and fibrous materials, such as spun or extruded fibers (cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics). Liquid aerosol-forming substrate storage components may include ceramic materials. Liquid aerosol-forming substrate storage components may have any suitable capillary action and porosity for use with different liquid aerosol-forming substrates having different physical properties.

[0061] The heating element may include a fifth part, the fifth part of which is located in the storage section. Unless otherwise specified, the term “storage section” may be used to refer to a storage section for storing a liquid aerosol-forming substrate or a storage section for a liquid aerosol-forming substrate. Unless otherwise specified, the term “storage section” may be used to refer to a storage section for storing a free-flowing liquid aerosol-forming substrate or a storage section for a free-flowing liquid aerosol-forming substrate.

[0062] The storage section may be configured to store, or may store, at least 0.2, 0.5, or 1 milliliter of liquid aerosol-forming substrate. The storage section may be configured to store, or may store, less than 2, 1.8, or 1.5 milliliters of liquid aerosol-forming substrate.

[0063] The heating element may be perforated. The heating element may be a mesh heating element. The heating element may include mesh. The first part, or the second part, or both the first and second parts may include perforations or mesh. The third part, or the fourth part, or both the third and fourth parts may include perforations or mesh.

[0064] Advantageously, a mesh heating element or a heating element containing a mesh can provide a large surface area in contact with the liquid aerosol-forming substrate. This large surface area can provide efficient vaporization of the liquid aerosol-forming substrate.

[0065] The heater assembly may include a second heating element. The features described in relation to the first heating element may be applied to the second heating element. Similarly, the features described in relation to a part of the first heating element may be applied to the corresponding part or section of the second heating element. For example, one or more of the materials and shapes of the first heating element may be applied to the second heating element. Alternatively, the second heating element may have a different shape or form from the heating element.

[0066] Advantageously, the second heating element can increase the vaporization rate of the liquid aerosol-forming substrate in the liquid aerosol-forming substrate storage component. Furthermore, the distance between the first and second heating elements can be selected to affect the temperature of the region of the liquid aerosol-forming substrate storage component during use. For example, regions of the liquid aerosol-forming substrate storage component where the first and second heating elements are close to each other may reach higher temperatures than regions where the first and second heating elements are further apart.

[0067] The second heating element may include the first part. The second heating element may include the second part. The second heating element may include the third part. The second heating element may include the fourth part. The second heating element may include the fifth part.

[0068] The second part may extend between the first and third parts. The third part may extend between the second and fourth parts.

[0069] The first part of the second heating element does not have to be embedded in the liquid aerosol-forming substrate storage component. The second part of the second heating element does not have to be embedded in the liquid aerosol-forming substrate storage component. The third part of the second heating element may be embedded in the liquid aerosol-forming substrate storage component. The fourth part of the second heating element does not have to be embedded in the liquid aerosol-forming substrate storage component. The fifth part of the second heating element may be located in the storage section.

[0070] This advantageously allows for the creation of more regions at relatively high temperatures and more regions at relatively low temperatures within the liquid aerosol-forming substrate storage component.

[0071] The second heating element may be woven into and outside the liquid aerosol-forming substrate storage component.

[0072] The second heating element may include one or more of the following: curves, undulations, folds, and corrugations.

[0073] The second heating element may be spaced apart from the first heating element in the lateral direction relative to its length. The second heating element may be spaced apart from the first heating element in the width direction. The second heating element may be located adjacent to the first heating element.

[0074] The second heating element may be a mesh heating element. The second heating element may include a mesh.

[0075] The first and second heating elements may not be electrically connected.

[0076] The first heating element may be configured to use induction heating.

[0077] The first and second heating elements may be able to operate independently. It may be possible to resistively or inductively heat the first heating element without substantially resistively or inductively heating the second heating element. It may be possible to raise the temperature of the first heating element without substantially raising the temperature of the second heating element. The first and second heating elements may be connected to different power sources.

[0078] The first part, the second part, or both the first and second parts of the heating element may be configured to heat to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. During use, the first part, the second part, or both the first and second parts of the heating element may be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius.

[0079] The third portion, or the fourth portion, or both of the third and fourth portions of the heating element may be configured to heat to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. During use, the third portion, or the fourth portion, or both of the third and fourth portions of the heating element may be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius.

[0080] The fifth portion of the heating element may be configured to be heated, and may be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius during use.

[0081] The liquid aerosol-forming substrate storage component may be configured to store, or may store, at least 0.02, 0.05, 0.1, 0.2, or 0.5 milliliters of liquid aerosol-forming substrate.

[0082] Another aspect of this disclosure provides a method for assembling a heater assembly. The heater assembly may be a heater assembly according to this disclosure. The method may include providing a liquid aerosol-forming substrate storage component. The method may include providing a heating element comprising a first part and a second part. The method may include embedding the first part of the heating element into a liquid aerosol-forming substrate storage component.

[0083] If the heating element includes a third portion, the method may include embedding the third portion of the heating element in a liquid aerosol-forming substrate storage component.

[0084] According to another aspect of this disclosure, a cartridge is provided. The cartridge may comprise a heater assembly according to this disclosure.

[0085] The cartridge may be configured to engage with and disengage from the aerosol generator. The aerosol generator may include a power supply. The power supply may be configured to supply power to the heating element. The power supply may be configured to supply power to the heating element only when the cartridge is engaged with the aerosol generator.

[0086] The cartridge may have an air intake. The cartridge may have an air outlet. The air intake may be in fluid communication with the air outlet. The heating element may be located downstream of the air intake. The heating element may be located upstream of the air outlet. During use, air may flow through the air intake, then across, traverse, pass through, or go through the heater assembly or heating element, and then pass through the air outlet.

[0087] The cartridge may be equipped with a mouthpiece. The mouthpiece may include an air outlet. When the cartridge is engaged with the aerosol generator during use, the user may inhale through the mouthpiece of the cartridge. This allows air to flow through the air intake, then across, traverse, pass through, or go through the heater assembly or heating element, and then through the air outlet.

[0088] Advantageously, providing airflow across, across, through, or via a heater assembly or heating element may allow the vapor formed by the heater assembly to be entrained in the airflow.

[0089] The cartridge may have first and second electrical contacts electrically connected to a heating element. The electrical contacts may include one or more of the following: tin, silver, gold, copper, aluminum, steel such as stainless steel, phosphor bronze, tin alloyed with antimony, tin alloyed with zirconium, tin alloyed with bismuth, or tin alloyed with other components that improve resistance to organic acids.

[0090] The electrical contacts may be configured to form an electrical connection with the corresponding electrical contacts on the aerosol generator when the cartridge engages with the aerosol generator.

[0091] The second part, or the fourth part, or both of the second and fourth parts of the heating element may be located within the airflow path between the air intake and the air outlet of the cartridge.

[0092] Advantageously, in use, this can increase the temperature of the airflow. Some users may prefer this. It can more accurately mimic the experience of smoking a conventional cigarette or cigar.

[0093] According to another aspect of this disclosure, an aerosol generating system is provided. The system may include a heater assembly according to this disclosure.

[0094] The aerosol generating system may include the cartridge according to this disclosure.

[0095] The system may include an aerosol generator. The system may also include a cartridge containing a heater assembly.

[0096] The cartridge may be configured to engage with the aerosol generator. The cartridge may also be configured to disengage from the aerosol generator.

[0097] The aerosol generation system may include a power source, such as a battery, in the aerosol generator of the aerosol generation system, for example. The power source may be configured to supply power to a heating element, which may be for heating the heating element. The power source may be configured to supply power to the heating element only when the cartridge is engaged with the aerosol generator.

[0098] The aerosol generator may include a controller. The controller may be configured to control the supply of power from the power source. Thus, the controller can control the heating of the heating element.

[0099] The power supply may be configured to supply power to the heating element, thereby resistively heating it. The power supply may also be configured to supply power to the heating element, thereby inductively heating it.

[0100] The aerosol generator may be configured to engage with and disengage from a cartridge via a snap-fit ​​connection, corresponding threads, or any other suitable means. The aerosol generator may be configured to receive at least a portion of the cartridge. For example, the aerosol generator may include a chamber configured to receive at least a portion of the cartridge.

[0101] The aerosol generator may be equipped with an air intake. The aerosol generator may be equipped with an air outlet. When the aerosol generator engages with a cartridge, the air outlet of the aerosol generator may be in fluid communication with the air intake of the cartridge.

[0102] A power supply may be electrically connected to the first and second electrical contacts of the device. These first and second electrical contacts may be configured to form an electrical connection with the corresponding first and second electrical contacts on the cartridge when the cartridge engages with the device. These corresponding first and second electrical contacts on the cartridge may be electrically connected to a heating element. Thus, the power supply may be configured to supply power to the heating element by passing an electric current through it.

[0103] The cartridge or aerosol generator may include an inductor, such as an induction coil. The heating element may be a susceptor material, or may contain a susceptor material.

[0104] A power supply can be configured to pass a current, such as a high-frequency alternating current, through an inductor so that the inductor generates a fluctuating electromagnetic field. This can then generate eddy currents and hysteresis losses within the susceptor material. This can heat the susceptor material. Therefore, a power supply using an inductor can be configured to inductively heat a heating element.

[0105] Suitable susceptor materials include those described above with reference to the heater assembly described herein.

[0106] The inductor may be an induction coil. The inductor may be located within a cartridge containing a heater assembly. The inductor may be positioned around a heating element, or around a portion of a heating element. For example, the inductor may be an induction coil and may be spirally arranged around a heating element, or around a portion of a heating element.

[0107] The inductor may be electrically connected to electrical contacts on the cartridge. When the cartridge engages with the aerosol generator, these electrical contacts may be electrically connected to corresponding electrical contacts on the device that are electrically connected to the device's power supply. When the cartridge engages with the device, the device's power supply may be configured to supply current to the inductor, generating a fluctuating electromagnetic field, thereby heating the susceptor material of the heating element.

[0108] An inductor, such as an induction coil, may be located within the aerosol generator. The inductor may be electrically connected to the power supply of the aerosol generator. The aerosol generator may be configured to engage with a heater assembly or a cartridge containing a heater assembly. For example, the device may have a chamber for receiving at least a portion of the heater assembly or at least a portion of the cartridge containing the heater assembly. The induction coil may be arranged around at least a portion of this chamber. For example, the induction coil may be spirally arranged around at least a portion of the chamber. Therefore, when the heater assembly or the cartridge containing the heater assembly engages with the device, the induction coil may be arranged around the heating element or a portion of the heating element, or may be spirally arranged. When at least a portion of the heater assembly or at least a portion of the cartridge containing the heater assembly is received within the chamber of the device, the power supply of the device may be configured to pass current through the inductor to generate a fluctuating electromagnetic field, thereby heating the susceptor material of the heating element.

[0109] As described above, induction heating can advantageously enable the manufacture of simple, inexpensive, and robust cartridges. Furthermore, induction heating can offer improved energy conversion compared to resistance heating.

[0110] The aerosol generating system may be a smoke inhalation system, such as an electrically operated smoking system. The aerosol generating system may be for recreational use. When in use, the aerosol generating system may be suitable for or configured to deliver nicotine to the user.

[0111] The aerosol generating system may be portable. The aerosol generating system may be comparable in size to a conventional cigar or cigarette. The smoking system may have an overall length of 30 to 200 millimeters. The smoking system may have an outer diameter of 5 to 30 millimeters. As used herein, the term “aerosol” refers to the dispersion of solid particles or droplets, or a combination of solid particles and droplets, in a gas. Aerosols may be visible or invisible. Aerosols may also include vapors of substances that are normally liquid or solid at room temperature, as well as solid particles or droplets, or a combination of solid particles and droplets.

[0112] As used herein, the term "aerosol-forming substrate" refers to a substrate having the ability to release volatile compounds that can form aerosols. The volatile compounds may be released by heating or burning the aerosol-forming substrate.

[0113] The aerosol-forming substrate may comprise multiple compounds. The compounds may have different boiling points. For example, the aerosol-forming substrate may comprise a first compound having a first boiling point at atmospheric pressure, and a second compound having a second boiling point at atmospheric pressure, where the first boiling point is higher than the second boiling point.

[0114] The aerosol-forming substrate may include an aerosol-forming compound. As used herein, the term “aerosol-forming compound” means any suitable compound or mixture of compounds that facilitates the formation of an aerosol, for example, a stable aerosol that is substantially resistant to thermal degradation at the operating temperature of the system, when used. Suitable aerosol-forming compounds are well known in the art and include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (e.g., dimethyl dodecanediol, dimethyl tetradecanediol).

[0115] The aerosol-forming substrate may contain nicotine. The aerosol-forming substrate may contain water. The aerosol-forming substrate may contain glycerol, also known as glycerin, which has a higher boiling point than nicotine. The aerosol-forming substrate may contain propylene glycol. The aerosol-forming substrate may contain plant-derived materials. The aerosol-forming substrate may contain homogenized plant-derived materials. The aerosol-forming substrate may contain tobacco. The aerosol-forming substrate may contain tobacco-containing materials. The tobacco-containing materials may contain volatile tobacco-flavoring compounds. These compounds may be released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may contain homogenized tobacco materials. The aerosol-forming substrate may contain other additives and components such as flavoring agents.

[0116] As used herein, the term “liquid aerosol-forming substrate” is used to refer to an aerosol-forming substrate in a condensed form. Therefore, “liquid aerosol-forming substrate” may be, or may contain, one or more of a liquid, gel, or paste. If the liquid aerosol-forming substrate is a gel or paste, or contains a gel or paste, the gel or paste may liquefy upon heating. For example, a gel or paste may liquefy when heated to a temperature below 50, 75, 100, 150, or 200 degrees Celsius.

[0117] As used herein, the term “heating element” refers to an element of a heater, an element configured to heat. For example, the term “heating element” may refer to an element configured to heat to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. The heating element, or a part thereof, may be configured to be resistively heated. Alternatively, or additionally, the heating element, or a part thereof, may be configured to be inductively heated.

[0118] As used herein, the term “embedded” may be used to mean enclosed, wrapped, sealed, surrounded, or enclosed. Furthermore, when a first component is “embedded” in a second component, this may mean that the first component is in contact with the second component. For example, when a portion of a heating element is described as being embedded in a component, this may mean that this portion of the heating element is surrounded by the component and in contact with the component. [Examples]

[0119] The present invention is defined in the claims. However, a non-exclusive list of non-limiting embodiments is provided below. One or more features of these embodiments may be combined with one or more features of other embodiments, forms, or aspects described herein.

[0120] Example 1: A heater assembly for use in an aerosol generation system, Liquid aerosol forming substrate storage component, A heating element comprising a first part and a second part, A heater assembly in which the first part of the heating element is embedded in the liquid aerosol-forming substrate storage component, and the second part of the heating element is not embedded in the liquid aerosol-forming substrate storage component. Example 2: The heater assembly according to Example 1, wherein the heating element comprises a third part and a fourth part, the third part of the heating element being embedded in a liquid aerosol-forming substrate storage component, and the fourth part not being embedded in a liquid aerosol-forming substrate storage component. Example 3: The heater assembly according to Example 2, wherein the second part of the heating element extends between the first part and the third part. Example 4: A heater assembly according to Example 2 or Example 3, wherein the third part of the heating element extends between the second part and the fourth part. Example 5: A heater assembly according to any of Examples 2 to 4, wherein the third and fourth parts are configured to be resistively heated. Example 6: A heater assembly according to any of Examples 2 to 5, wherein the third and fourth parts include an electrical resistance material. Example 7: A heater assembly according to any of Examples 1 to 6, wherein the first and second parts are configured to be resistively heated. Example 8: A heater assembly according to any of Examples 1 to 7, wherein the first and second parts include an electrical resistance material. Example 9: A heater assembly according to any of Examples 2 to 4, wherein the third and fourth parts are configured to be induction heated. Example 10: A heater assembly according to any of Examples 2 to 4 or 9, wherein the third and fourth parts comprise a susceptor material. Example 11: A heater assembly according to any of Examples 1-4, 9, or 10, configured such that a first part and a second part are induction heated. Example 12: A heater assembly according to any of Examples 1-4, 9, 10, or 11, wherein the first and second parts comprise a susceptor material. Example 13: A heater assembly according to any of Examples 1 to 12, wherein the heating element includes a strip-shaped material. Example 14: A heater assembly according to any of Examples 1 to 13, wherein the cross-section of the heating element changes along the length of the heating element. Example 15: A heater assembly according to any of Examples 1 to 14, wherein the minimum cross-sectional area along the length of the heating element is at least 10 percent smaller than the maximum cross-sectional area along the length of the heating element. Example 16: A heater assembly according to any of Examples 1 to 15, wherein the width or thickness of the heating element, or both, varies along the length of the heating element. Example 17: A heater assembly according to any one of Examples 1 to 16, wherein the heating element is woven into and outside the liquid aerosol-forming substrate storage component. Example 18: A heater assembly according to any of Examples 1 to 17, wherein the heating element includes one or more of the following: curves, undulations, folds, and corrugations. Example 19: A heater assembly according to any of Examples 1 to 18, wherein the heating element includes one or more of the following: irregular undulations along the length of the heating element and irregular waveforms. Example 20: A heater assembly according to any of Examples 1 to 19, wherein the frequency of the fluctuations or waveform of the heating element changes along the length of the heating element. Example 21: A heater assembly according to any of Examples 1 to 20, wherein the amplitude of the undulation or waveform of the heating element changes along the length of the heating element. Example 22: A heater assembly according to any one of Examples 1 to 21, comprising a storage section for storing a liquid aerosol-forming substrate. Example 23: The heater assembly according to Example 22, wherein the storage section is in fluid communication with the liquid aerosol-forming substrate storage component. Example 24: The heater assembly according to Example 22 or 23, wherein the heating element includes a fifth portion, and the fifth portion is located within the storage portion. Example 25: The heater assembly according to Example 22, 23, or 24, wherein the storage section contains at least 1 milliliter of liquid aerosol-forming substrate. Example 26: A heater assembly according to any of Examples 1 to 25, including a second heating element. Example 27: The heater assembly according to Example 26, wherein the second heating element is woven into and out of the liquid aerosol-forming substrate storage component. Example 28: The heater assembly according to Example 26 or 27, wherein the second heating element includes one or more of the following: curves, undulations, folds, and corrugations. Example 29: A heater assembly according to any of Examples 26 to 28, wherein the second heating element is spaced apart from the heating element in the lateral direction relative to the length of the heating element. Example 30: A heater assembly according to any of Examples 26 to 29, wherein the second heating element is a mesh heating element. Example 31: A heater assembly according to any one of Examples 1 to 30, wherein both the first and second parts are heated to at least 50 degrees Celsius when in use. Example 32: A heater assembly according to any of Examples 1 to 31, wherein the heating element is a mesh heating element. Example 33: A heater assembly according to any one of Examples 1 to 32, wherein the liquid aerosol-forming substrate storage component includes a capillary-holding material. Example 34: A heater assembly according to any one of Examples 1 to 33, wherein the liquid aerosol-forming substrate storage component is configured to store at least 0.05 milliliters of liquid aerosol-forming substrate. Example 35: A heater assembly according to any one of Examples 1 to 34, wherein at least 0.05 milliliters of liquid aerosol-forming substrate are stored in a liquid aerosol-forming substrate storage component. Example 36: A cartridge comprising a heater assembly as described in any of Examples 1 to 35. Example 37: A method for assembling a heater assembly described in any of Examples 1 to 35, To provide a liquid aerosol-forming substrate storage component, To provide a heating element including a first part and a second part, A method comprising embedding a first portion of a heat-generating element in a liquid aerosol-forming substrate storage component. Example 38: An aerosol generating system comprising a heater assembly as described in any of Examples 1 to 35. Example 39: The aerosol generating system according to Example 38, wherein the system comprises a cartridge having an aerosol generator and a heater assembly. Example 40: The aerosol generating system according to Example 39, wherein the cartridge is configured to engage with and disengage from an aerosol generating device. Example 41: The aerosol generating system according to any one of Examples 38, 39, or 40, wherein the aerosol generating system comprises a power supply configured to power a heating element in order to heat the heating element. Example 42: The aerosol generating system according to Example 39 or 40, wherein the aerosol generator includes a power supply configured to supply power to a heating element in order to heat the heating element. Example 43: The aerosol generating system according to Example 41 or 42, wherein the power supply is configured to power a heating element in order to resistively heat the heating element. Example 44: The aerosol generating system according to Example 41 or 42, wherein the power supply is configured to provide power to a heating element in order to inductively heat the heating element. Example 45: An aerosol generating system according to any of Examples 38 to 44, wherein the aerosol generating system has an overall length of 30 mm to 200 mm. Example 46: An aerosol generating system according to any of Examples 38 to 45, wherein the aerosol generating system has an outer diameter of 5 mm to 30 mm. Example 47: An aerosol generating system according to any one of Examples 38 to 46, wherein the aerosol generating system is portable. Example 48: The aerosol generating system is an aerosol extraction system, as described in any of Examples 38 to 47. [Brief explanation of the drawing]

[0121] Here, we will further describe the embodiments with reference to the figures.

[0122] [Figure 1] Figure 1 shows a schematic cross-sectional view of the first aerosol generation system, including a cartridge incorporating the first heater assembly. [Figure 2] Figure 2 shows a schematic cross-sectional view of the first heater assembly. [Figure 3] Figure 3 shows a schematic perspective view of the first heater assembly. [Figure 4] Figure 4 is a schematic cross-sectional view of the second aerosol generation system, including a cartridge incorporating the second heater assembly. [Figure 5] Figure 5 shows a schematic cross-sectional view of the second heater assembly. [Figure 6] Figure 6 shows a schematic perspective view of the second heater assembly. [Modes for carrying out the invention]

[0123] Figure 1 shows a schematic cross-sectional view of the first aerosol generating system 100. The aerosol generating system 100 comprises an aerosol generator 150 and a cartridge 200. In this embodiment, the aerosol generating system 100 is an electrically operated smoking system.

[0124] The aerosol generator 150 is portable and has a size comparable to a conventional cigar or cigarette. The device 150 includes a battery 152, such as a lithium iron phosphate battery, and a controller 154 electrically connected to the battery 152. The device 150 also includes two electrical contacts 156 and 158 electrically connected to the battery 152. This electrical connection is wired and is not shown in Figure 1.

[0125] The cartridge 200 comprises first and second electrical contacts 214, 216, an air intake 202, an air outlet 204, and a first heater assembly 300. The air intake 202 is in fluid communication with the air outlet 204. The heater assembly 300 is located downstream of the air intake 202 and upstream of the air outlet 204. The heater assembly 300 includes a liquid aerosol-forming substrate storage component 302, which is in fluid communication with a liquid aerosol-forming substrate storage section 303. The heater assembly 300 also includes a heating element 304. The first and second electrical contacts 214, 216 are electrically connected to the heating element 304.

[0126] In this system 100, the liquid aerosol-forming substrate can be any suitable substrate, but contains approximately 74% by weight glycerin, 24% by weight propylene glycol, and 2% by weight nicotine. At atmospheric pressure, nicotine has a boiling point of approximately 247 degrees Celsius, glycerin has a boiling point of approximately 290 degrees Celsius, and propylene glycol has a boiling point of approximately 188 degrees Celsius. Therefore, when this liquid aerosol-forming substrate is initially heated to form an aerosol, some systems may vaporize an undesirably large amount of propylene glycol (which has the lowest boiling point of the compounds forming the substrate). This can lead to the delivery of less desirable aerosols to the user, such as an aerosol containing a lower-than-desirable proportion of nicotine. This may also result in undesirable changes in the relative ratios of the compounds in the substrate over a longer period of time. The present invention can eliminate or at least reduce these undesirable effects.

[0127] The heating element 304 is a strip-shaped material. In this example, the material is stainless steel, but any suitable material can be used. The heating element 304 comprises a first portion 306, a second portion 308, a third portion 310, and a fourth portion 312. The second portion 308 extends between the first portion 306 and the third portion 310. The third portion 310 extends between the second portion 308 and the fourth portion 312. The first portion 306 and the third portion 310 are embedded in the liquid aerosol-forming substrate storage component 302. The second portion 308 and the fourth portion 312 are not embedded in the liquid aerosol-forming substrate storage component 302. In the example shown in Figure 1, the second portion 308 and the fourth portion 312 are located in the airflow path between the air intake 202 and the air outlet 204 of the cartridge 200.

[0128] In Figure 1, the aerosol generator 150 is engaged with the cartridge 200. In this embodiment, the cartridge 200 engages with the aerosol generator 150 via threads 206 of the cartridge 200 that engage with the corresponding threads 162 of the aerosol generator 150.

[0129] The liquid aerosol-forming substrate storage component 302 in this embodiment is a capillary material having a fibrous structure. In the embodiment shown in Figure 1, the capillary material is formed from polyester, but any suitable material can be used.

[0130] During use, the user inhales smoke from the air outlet 204 of the cartridge 200. Simultaneously, the user presses a button (not shown) on the aerosol generator 150. Pressing this button sends a signal to the controller 154, which in turn supplies power from the battery 152 to the heating element 304 via the device's electrical contacts 156, 158 and the cartridge's electrical contacts 214, 216. This causes current to flow through the heating element 304, thereby resistively heating it. In other embodiments, an airflow sensor or pressure sensor is located inside the cartridge 200 and electrically connected to the controller 154. The airflow sensor or pressure sensor detects that the user is inhaling smoke from the air outlet 204 of the cartridge 200 and sends a signal to the controller 154 to supply power to the heating element 304. Thus, in these embodiments, the user does not need to press a button to heat the heating element 304.

[0131] When the heating element 304 is heated, regions of relatively high temperature and regions of relatively low temperature are generated within the liquid aerosol-forming substrate storage component 302. Regions of relatively low temperature may be generated in areas where the heating element 304 is closer to the storage section 303 of the liquid aerosol-forming substrate. This is because the heat from the heating element 304 in these areas is dissipated more quickly into the storage section 303. Regions of relatively low temperature may be generated in areas further away from the heating element. Regions of relatively high temperature may be generated due to the shape of the heating element. For example, the heating element may be shaped such that a larger volume or larger surface area of ​​the heating element present in a given volume at a first position within the liquid aerosol-forming substrate storage component is present in the same given volume at a second position within the liquid aerosol-forming substrate storage component. In this case, the average temperature of the liquid aerosol-forming substrate at the first position may be higher than the average temperature of the liquid aerosol-forming substrate at the second position.

[0132] By generating regions of higher and lower temperatures, the compounds of the liquid aerosol-forming substrate having higher and lower boiling points in the liquid aerosol-forming substrate storage component 302 are vaporized simultaneously. Furthermore, by generating regions of higher and lower temperatures, the compounds of the liquid aerosol-forming substrate having higher and lower boiling points in the liquid aerosol-forming substrate storage component 302 are vaporized at a desired rate.

[0133] As the user inhales smoke from the air outlet 204 of the cartridge 200, air is drawn into the air intake 202. This air then moves across the heater assembly 300 towards the air outlet 204. This airflow entrains vapor formed by the heating element 304, which heats the liquid aerosol-forming substrate in the liquid aerosol-forming substrate storage component 302. As described above, the vapor contains different compounds with different boiling points in desired proportions, generating higher and lower temperature regions. This entrained vapor is then cooled and condenses to form an aerosol. This aerosol is then delivered to the user via the air outlet 204. As the liquid aerosol-forming substrate in the liquid aerosol-forming substrate storage component 302 is heated, vaporized, and entrained by the airflow, the liquid aerosol-forming substrate from the storage unit 303 moves into the liquid aerosol-forming substrate storage component 302. This liquid aerosol-forming substrate from the storage section 303 effectively replaces the vaporized liquid aerosol-forming substrate. The liquid aerosol-forming substrate from the storage section 303 may also be drawn into the liquid aerosol-forming substrate storage component 302, at least partially by capillary action. This is because the liquid aerosol-forming substrate storage component 302 is a capillary material having a fibrous structure.

[0134] Figure 2 shows a schematic cross-sectional view of the first heater assembly 300. In Figure 2, the width of the heating element 304 is in the direction toward the drawing and may vary, but is constant in the example shown in Figure 2. However, as shown in Figure 2, the thickness of the heating element 304 is not constant. Rather, the thickness gradually decreases from the second part 308 to the third part 310, and then gradually increases from the third part 310 to the fourth part 312. The minimum thickness of the heating element 304 is in the third part 310, which is embedded in the liquid aerosol forming substrate storage component 302. This minimum thickness of the heating element 304 is about 50 percent of the maximum thickness of the heating element in the first part 306. Therefore, the resistance of the third part 310 is greater than that of the other parts, and during use, the third part 310 resistively heats to a higher temperature than the other parts. This can advantageously raise the temperature of the liquid aerosol forming substrate near the third part 310 of the heating element 304.

[0135] Figure 3 shows a schematic perspective view of the first heater assembly 300. As shown in Figure 3, the heating element 304 includes a curve and is woven into and out of the liquid aerosol-forming substrate storage component 302. The ends of the heating element 304 extend from the liquid aerosol-forming substrate storage component 302, allowing for a simple electrical connection to the electrical contacts of the cartridge 200 (not shown in Figure 3).

[0136] Figure 4 shows a schematic cross-sectional view of the second aerosol generating system 400. The aerosol generating system 400 comprises a cartridge 500 incorporating an aerosol generator 450 and a second heater assembly 600. In this embodiment, the aerosol generating system 400 is an electrically operated smoking system.

[0137] The aerosol generator 450 is portable and has a size comparable to a conventional cigar or cigarette. The device 450 includes a battery 452, such as a lithium iron phosphate battery, and a controller 454 electrically connected to the battery 452. The device 450 also includes an induction coil 456 electrically connected to the battery 452. The device 450 also includes an air intake 458 and an air outlet 460 that is in fluid communication with the air intake 458.

[0138] The cartridge 500 comprises an air intake 502, an air outlet 504, and a second heater assembly 600. The air intake 502 is in fluid communication with the air outlet 504. The heater assembly 600 is positioned downstream of the air intake 502 and upstream of the air outlet 504. As shown in Figure 4, when the cartridge 500 is engaged with the aerosol generator 450, the air outlet 460 of the device 450 is adjacent to the air intake 502 of the cartridge 500. Therefore, during use, when a user inhales smoke from the air outlet 504 of the cartridge 500, the air flows through the air intake 458 of the device 450, then through the air outlet 460 of the device 450, then through the air intake 502 of the cartridge 500, then through the heater assembly 600, and then through the air outlet 504 of the cartridge 500.

[0139] In Figure 4, the cartridge 500 is engaged with the aerosol generator 450. In this embodiment, the cartridge 500 is engaged with the aerosol generator 450 via openings 506, 508 that form a snap-fit ​​connection with corresponding projections 462, 464 on the aerosol generator 450.

[0140] The heater assembly 600 comprises a first heating element 604, a second heating element (not visible in Figure 4), a storage section 603 for a liquid aerosol-forming substrate, and a liquid aerosol-forming substrate storage component 602 that is in fluid communication with the storage section 603. The second heating element 605 is not visible in Figure 4, but is visible in Figure 6.

[0141] In this system 400, the liquid aerosol-forming substrate contains approximately 98% by weight of glycerin and 2% by weight of nicotine, but any suitable substrate can be used. At atmospheric pressure, nicotine has a boiling point of approximately 247 degrees Celsius, and glycerin has a boiling point of approximately 290 degrees Celsius. Therefore, when this liquid aerosol-forming substrate is initially heated to form an aerosol, some systems may vaporize an undesirably large amount of nicotine (which has the lowest boiling point of the compounds forming the substrate). This can lead to the delivery of a less desirable aerosol to the user. This can also lead to undesirable changes in the relative ratio of the compounds in the substrate over a longer period of time. The present invention can eliminate or at least reduce these undesirable effects.

[0142] The first heating element 604 includes a strip-shaped susceptor material. In this example, the susceptor material is aluminum, but any suitable susceptor material can be used. The first heating element 604 includes a plurality of parts embedded in the liquid aerosol-forming substrate storage component 602 and a plurality of parts not embedded in the liquid aerosol-forming substrate storage component 602. Of the parts not embedded in the liquid aerosol-forming substrate storage component 602, two are located within the storage section 603.

[0143] In the example shown in Figure 4, the second heating element 605 is identical to the first heating element 604, but two (or more) different heating elements may be used. The second heating element 605 is located adjacent to the first heating element 604.

[0144] The liquid aerosol-forming substrate storage component 602 in this embodiment is a capillary material having a fibrous structure. The capillary material is formed from polyester, but any suitable material may be used.

[0145] During use, the user inhales smoke from the air outlet 504 of the cartridge 500. Simultaneously, the user presses a button (not shown) on the aerosol generator 450. Pressing this button sends a signal to the controller 454, which in turn causes the battery 452 to supply a high-frequency current to the induction coil 456. This causes the induction coil 456 to generate a fluctuating electromagnetic field. The first heating element 604 and the second heating element 605 are positioned within this field. Thus, this fluctuating electromagnetic field generates eddy currents and hysteresis losses in the first heating element 604 and the second heating element 605. Consequently, the first heating element 604 and the second heating element 605 are inductively heated. In other embodiments, an airflow sensor or pressure sensor is located within the device 450 and electrically connected to the controller 454. An airflow sensor or pressure sensor detects that the user is drawing smoke from the air outlet 504 of the cartridge 500 and sends a signal to the controller 454 to supply a high-frequency current to the induction coil 456, thereby heating the first heating element 604 and the second heating element 605. Therefore, in these embodiments, the user does not need to press a button to heat the first heating element 604 and the second heating element 605.

[0146] When the first heating element 604 and the second heating element 605 are heated, regions of relatively high temperature and regions of relatively low temperature are generated within the liquid aerosol-forming substrate storage component 602. The regions of lower temperature may be generated in areas where the heating element 604 is closer to the storage section 603 of the liquid aerosol-forming substrate. This is because the heat from the heating element 604 in these areas is dissipated more quickly into the storage section 603. Regions of relatively low temperature may be generated in areas further away from the heating elements. Regions of relatively high temperature may be generated due to the shape of the heating elements. For example, the heating elements may be shaped such that a larger volume or larger surface area of ​​the heating elements present in a given volume at a first position within the liquid aerosol-forming substrate storage component is present in the same given volume at a second position within the liquid aerosol-forming substrate storage component. In this case, the average temperature of the liquid aerosol-forming substrate at the first position may be higher than the average temperature of the liquid aerosol-forming substrate at the second position.

[0147] By generating regions of higher and lower temperatures, the compounds of the liquid aerosol-forming substrate having higher and lower boiling points in the liquid aerosol-forming substrate storage component 602 are simultaneously vaporized. Furthermore, by generating regions of higher and lower temperatures, the compounds of the liquid aerosol-forming substrate having higher and lower boiling points in the liquid aerosol-forming substrate storage component 302 are vaporized at a desired rate.

[0148] As the user draws air into the air outlet 504 of the cartridge 500, air is drawn into the air intake 458 of the device 450, then through the air outlet 460 of the device 450, and then through the air intake 502 of the cartridge 500. This air then moves around the heater assembly 600 toward the air outlet 504. This airflow entrains vapor formed by heating the liquid aerosol-forming substrate by the first heating element 604 and the second heating element 605. As described above, the vapor contains different compounds with different boiling points in desired proportions, so that higher and lower temperature regions are generated. This entrained vapor is then cooled and condenses to form an aerosol. This aerosol is then delivered to the user via the air outlet 504.

[0149] Figure 5 shows a schematic cross-sectional view of the second heater assembly 600.

[0150] The first heating element 604 comprises a first portion 606, a second portion 608, a third portion 610, a fourth portion 612, a fifth portion 614, a sixth portion 616, a seventh portion 618, an eighth portion 620, and a ninth portion 622. The first portion 606, the third portion 610, the fifth portion 614, the seventh portion 618, and the ninth portion 622 are embedded in the liquid aerosol-forming substrate storage component 602. The second portion 608, the fourth portion 612, the sixth portion 616, and the eighth portion 620 are not embedded in the liquid aerosol-forming substrate storage component 602. The second portion 608 and the eighth portion 620 are located in the airflow path between the air intake 502 and the air outlet 504 of the cartridge 500. The fourth portion 612 and the sixth portion 616 are located in the storage section 603 of the liquid aerosol-forming substrate.

[0151] In Figure 5, various thicknesses of the first heating element 604 can be seen. The central section of the fifth portion 614 is thinner compared to the rest of the first heating element 604. Specifically, the thickness of the central section of the fifth portion 616 is about 30 percent of the thickness of the rest of the first heating element 604. As shown in Figure 5, the fifth portion 614 also includes a corrugated shape. The region of the liquid aerosol-forming substrate storage component 602 around the fifth portion 614 may rise to a relatively higher temperature than other regions of the liquid aerosol-forming substrate storage component 602. This is because, as the fifth portion 614 of the heating element 604 is thinner, the fifth portion 614 can be inductively heated to a higher temperature than other parts of the heating element 604. Alternatively, or additionally, the waveform in the fifth portion 614 means that the region of the liquid aerosol-forming substrate storage component 602 around the fifth portion 614 contains a heating element 604 with a larger volume and surface area than other regions of the liquid aerosol-forming substrate storage component 602 of similar size. Therefore, more heat can be transferred from the heating element 604 into the region of the liquid aerosol-forming substrate storage component 602 around the fifth portion 614 than in other regions.

[0152] Figure 6 shows a schematic perspective view of the second heater assembly 600. In Figure 6, the second heating element 605 is visible. The second heating element 605 is identical to the first heating element 604 and is located adjacent to it. Thus, the second heating element 605 similarly has a portion embedded in the liquid aerosol forming substrate storage component 602, a portion located within the storage section 603, and a portion located in the airflow path between the air intake 502 and the air outlet 504 of the cartridge 500. In Figure 6, the second portion 608 and the eighth portion 620 of the first heating element 604 are also visible.

[0153] The heater assemblies described herein can provide a higher temperature region and a lower temperature region in the liquid aerosol-forming substrate storage component. Alternatively, or additionally, the heater assemblies can provide a region in the liquid aerosol-forming substrate storage component where the temperature rises at a faster rate and a region where the temperature rises at a slower rate. Advantageously, as described above, this allows for the simultaneous vaporization of liquid aerosol-forming substrate compounds having higher and lower boiling points at desired rates.

[0154] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc., should be understood in all cases as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein. Thus, in this context, the number A is understood as A ± 10 percent. In this context, the number A may be considered to include a number that falls within the general standard error to the measurement of the characteristic that the number A modifies. In some cases as used in the appended claims, the number A may deviate by the percentages listed above, provided that the amount of deviation does not substantially affect the basic and novel characteristics of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein.

Claims

1. A heater assembly for use in an aerosol generation system, Liquid aerosol forming substrate storage component, A storage section for a free-flowing liquid aerosol-forming substrate, wherein the storage section is in fluid communication with the liquid aerosol-forming substrate storage component, A heating element comprising a first part, a second part, and further parts, A heater assembly in which the first portion of the heating element is embedded in the liquid aerosol-forming substrate storage component, the second portion of the heating element is not embedded in the liquid aerosol-forming substrate storage component, and the further portion of the heating element is located in the storage section.

2. The heater assembly according to claim 1, wherein the heating element comprises a third portion and a fourth portion, the third portion of the heating element being embedded in the liquid aerosol-forming substrate storage component, and the fourth portion not being embedded in the liquid aerosol-forming substrate storage component.

3. The heater assembly according to claim 2, wherein the second portion of the heating element extends between the first portion and the third portion, and the third portion of the heating element extends between the second portion and the fourth portion.

4. The heater assembly according to any one of claims 1 to 3, wherein the heating element comprises a strip-shaped material having a length, a width perpendicular to the length, and a thickness perpendicular to the length and the width, wherein the length is greater than the width and the thickness is greater.

5. The heater assembly according to any one of claims 1 to 4, wherein the cross-section of the heating element changes along the length of the heating element.

6. The heater assembly according to any one of claims 1 to 5, wherein the heating element extends between a first end and a second end, and the heating element has a first cross-sectional area at a first point between the first end and the second end, a second cross-sectional area at a second point between the first point and the second end, and a third cross-sectional area at a third point between the second point and the second end, and each of the first cross-sectional area and the third cross-sectional area is greater than or less than the second cross-sectional area.

7. The heater assembly according to any one of claims 1 to 6, wherein the heating element is woven into and out of the liquid aerosol forming substrate storage component.

8. The heater assembly according to any one of claims 1 to 7, wherein the heating element includes one or more of the following: curves, undulations, folds, and corrugations.

9. A heater assembly according to any one of claims 1 to 8, comprising a second heating element.

10. The heater assembly according to claim 9, wherein the second heating element comprises a first portion and a second portion, the first portion of the second heating element being embedded in the liquid aerosol-forming substrate storage component, and the second portion of the second heating element not being embedded in the liquid aerosol-forming substrate storage component.

11. The heater assembly according to any one of claims 1 to 10, wherein both the first part and the second part are heated to at least 50 degrees Celsius when in use.

12. An aerosol generating system comprising a heater assembly according to any one of claims 1 to 11.

13. The aerosol generating system according to claim 12, wherein the system comprises an aerosol generator and a cartridge including the heater assembly, and the cartridge is configured to engage with and disengage from the aerosol generator.

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