Aerosol delivery system

Abstract

An aerosol delivery system (10) for generating an aerosol from an aerosol generating substrate is described. The aerosol delivery system includes a cartridge (30) for use in the aerosol delivery system for generating an aerosol from an aerosol generating substrate. The cartridge is configured to be connected to and disconnected from a control unit (20) of the aerosol delivery system via an interface. The cartridge includes a heating element (14) configured to aerosolize a portion of the aerosol generating substrate in the vicinity of a heating element, and the heating element provides at least a portion of the cartridge interface surface. The cartridge interface surface is configured to be adjacent to the control unit interface surface when the cartridge (30) and the control unit (20) are connected via an interface.

Description

Technology Field

[0001] The present disclosure relates to an aerosol delivery system, a cartridge for use with the aerosol delivery system, an induction assembly and a control unit, and a method for operating the aerosol delivery system. Background Technology

[0002] Many electronic vapor delivery systems, such as e-cigarettes and other electronic nicotine delivery systems that deliver nicotine through vaporized liquids, are formed from two main components or sections: a cartridge or cartomizer section and a control unit (battery section). The cartomizer generally includes a liquid reservoir and an atomizer for vaporizing the liquid. These parts may collectively be referred to as an aerosol source. The atomizer typically combines porous or wicking and heating functions to transport the liquid from the reservoir to a location where it is heated and vaporized. For example, the atomizer may be implemented as an electric heater, which may be a resistance wire formed into a coil or other shape for resistance (Joule) heating or a susceptor for induction heating, and as a porous element with capillary or wicking capabilities located near the heater that absorbs liquid from the reservoir and transports it to the heater. The control unit generally includes a battery to supply power for operating the system. Electric power from the battery is supplied to activate the heater, which heats up to vaporize a small amount of liquid supplied from the reservoir. The vaporized liquid is then inhaled by the user.

[0003] The components of a cartomizer may be intended for short-term use only; accordingly, the cartomizer is a disposable component of the system, also referred to as a consumable. In contrast, the control unit is intended for multiple uses, typically involving a series of cartomizers that the user replaces whenever each cartomizer is depleted. Consumable cartomizers are supplied to the consumer with a reservoir pre-filled with liquid and are intended to be discarded when the reservoir is empty. For convenience and safety, the reservoir is designed to be sealed and not easily refilled, as the liquid can be difficult to handle. It is simpler for the user to replace the entire cartomizer when a new liquid supply is required.

[0004] In this context, it is desirable for atomizers to be simple to manufacture and contain few components, while still providing an appropriate amount of vapor upon activation of the heater. Therefore, atomizers can be manufactured efficiently in large quantities at low cost with minimal waste, without compromising the user's vaping experience. Consequently, atomizers with simple designs that enable efficient heating are of interest.

[0005] Various approaches intended to help solve some of these problems are described.

[0006] According to a first aspect of specific embodiments, a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate is provided, wherein the cartridge is configured to be connected to and disconnected from a control unit of the aerosol delivery system through an interface, and the cartridge comprises a heating element configured to aerosolize a portion of the aerosol generating substrate in the vicinity of a heating element, wherein the heating element provides at least a portion of the cartridge interface surface; and the cartridge interface surface is configured to be adjacent to the control unit interface surface when the cartridge and the control unit are connected through the interface.

[0007] In some examples according to the first aspect, the heating element includes a flat surface that provides at least a portion of the cartridge interface surface.

[0008] In some examples according to the first aspect, the cartridge includes a spacer that protrudes outward from the cartridge interface surface; optionally, the spacer protrudes outward from the cartridge interface surface by a distance ranging from 0.3 mm to 2 mm.

[0009] In some examples according to the first aspect, the heating element includes a plurality of apertures extending through the heating element.

[0010] In some examples according to the first aspect, a plurality of openings are arranged in a pattern, and the density of the plurality of openings varies from the peripheral edge of a portion of the cartridge interface surface toward the center of a portion of the cartridge interface surface; optionally, the density of the plurality of openings increases from the peripheral edge of a portion of the cartridge interface surface toward the center of a portion of the cartridge interface surface.

[0011] In some examples according to the first aspect, the heating element includes a resistive track provided on the cartridge interface surface.

[0012] In some examples according to the first aspect, the heating element comprises a susceptor; optionally, the susceptor comprises a planar element having a thickness of one or more of the ranges of 20 μm to 70 μm, 30 μm to 60 μm, and 40 μm to 55 μm.

[0013] In some examples according to the first aspect, the cartridge includes a removable cover adjacent to a portion of the cartridge interface surface.

[0014] According to a second aspect of specific embodiments, a mouthpiece for use in an aerosol delivery system is provided, the mouthpiece is configured to hold a cartridge according to a first aspect within a cavity, the mouthpiece comprises: an outlet for the aerosol delivery system; and an opening mechanism configured to allow the mouthpiece to move between a first configuration and a second configuration, wherein in the first configuration, the cavity is at least partially exposed to allow the cartridge to be inserted and / or removed, and in the second configuration, the mouthpiece is configured to hold a cartridge provided within the cavity.

[0015] In some examples according to the second aspect, the mouthpiece comprises at least one component of the connecting mechanism, and the connecting mechanism is configured to hold the mouthpiece in the second configuration.

[0016] According to a third aspect of specific embodiments, an induction assembly for use with a cartridge according to a first aspect is provided, wherein the induction assembly comprises an induction element operable to induce a current flow in a heating element of the cartridge to induce heating of the heating element, thereby aerosolizing a portion of an aerosol generating substrate near the heating element, and the induction assembly provides at least a portion of a control unit interface surface, and the induction element is provided near the control unit interface surface.

[0017] In some examples according to the third aspect, the inductive element comprises a pair of adjacent coils rotating in opposite directions within a single plane.

[0018] According to a fourth aspect of specific embodiments, a control unit for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate is provided, wherein the control unit comprises: an induction assembly of a third aspect; a power supply device for supplying power to an induction element; and a control circuit for controlling the power supply to the induction element, wherein the control circuit is configured to drive the induction element to induce a current flow in a heating element to induce heating of the heating element, thereby vaporizing a portion of the aerosol generating substrate near the heating element.

[0019] According to a fifth aspect of specific embodiments, an aerosol delivery system for generating an aerosol from an aerosol generating substrate is provided, wherein the aerosol delivery system comprises a cartridge of a first aspect; a control unit of a fourth aspect, and an air path is provided between a cartridge interface surface and a control unit interface surface;

[0020] In some examples according to the fifth aspect, the aerosol delivery system includes a mouthpiece of the second aspect.

[0021] In some examples according to the fifth aspect, the separation distance between the cartridge interface surface and the control unit interface surface is in the range of 0.3 mm to 2 mm;

[0022] In some examples according to the fifth aspect, the separation distance between the cartridge interface surface and the control unit interface surface is in the range of 0.5 mm to 1.5 mm.

[0023] According to a sixth aspect of specific embodiments, a method for generating an aerosol from an aerosol generating substrate in an aerosol delivery system is provided, wherein the aerosol delivery system comprises a cartridge and a control unit, the cartridge comprises a heating element providing at least a portion of a cartridge interface surface; the control unit comprises a control unit interface surface, and the method comprises the steps of connecting the cartridge to the control unit through an interface — the cartridge interface surface is adjacent to the control unit interface surface when the cartridge and the control unit are connected through an interface — and heating the heating element by passing an electric current through the heating element to vaporize a portion of the aerosol generating substrate near the heating element.

[0024] These aspects and additional aspects of specific embodiments are described in the appended independent and dependent claims, and also in the provisions provided at the end of this specification. It will be understood that the features of the dependent claims may be combined with one another and with the features of the independent claims in combinations other than those explicitly described in the claims. Furthermore, the approach described herein is not limited to specific embodiments such as those described below, but includes and considers any suitable combination of features presented herein, such as combinations of features of the independent and dependent claims and features present in the provisions provided at the end of this specification. For example, a heater for a steam supply system or a steam supply system including a heater may be provided according to the approaches described herein, appropriately including one or more of the various features described below. Brief explanation of the drawing

[0025] Various embodiments of the present invention will be described in detail only by way of example with reference to the following drawings: FIG. 1 illustrates a schematic diagram of an example of an aerosol / vapor delivery system according to aspects of the present disclosure. FIG. 2 illustrates a cross-sectional view through an example of an aerosol delivery system according to aspects of the present disclosure. FIG. 3 illustrates a cross-sectional view through an example of an aerosol delivery system according to aspects of the present disclosure. FIG. 4 illustrates a cross-sectional view of the cartridge interface surface of a cartridge according to aspects of the present disclosure. FIG. 5 illustrates a cross-sectional view of the cartridge interface surface of a cartridge according to aspects of the present disclosure. FIG. 6 illustrates a schematic diagram of an example of a mouthpiece, cartridge, and induction assembly for use in an aerosol / vapor delivery system according to aspects of the present disclosure. FIG. 7 illustrates a schematic diagram of an example of a mouthpiece, cartridge, and induction assembly for use in an aerosol / vapor delivery system according to aspects of the present disclosure. FIG. 8 illustrates a flowchart depicting a method of generating an aerosol from an aerosol generating substrate in an aerosol delivery system according to the present disclosure. Specific details for implementing the invention

[0026] Aspects and features of specific examples and embodiments are discussed and described herein. Some aspects and features of specific examples and embodiments may be implemented in a conventional manner and are not discussed or described in detail for the sake of brevity. Accordingly, it will be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail may be implemented according to any conventional techniques for implementing such aspects and features.

[0027] According to the present disclosure, a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate is described, wherein the cartridge is configured to be connected to and disconnected from a control unit of the aerosol delivery system via an interface. The cartridge includes a heating element configured to aerosolize a portion of the aerosol generating substrate in the vicinity of the heating element. The heating element provides at least a portion of the cartridge interface surface. The cartridge interface surface is configured to be adjacent to the control unit interface surface when the cartridge and the control unit are connected via an interface.

[0028] The provision of such a cartridge may be advantageous in that the cartridge configuration provides a relatively simple design in which the heating element provides the base of the cartridge. This system also enables efficient aerosolization due to the relatively large surface area of ​​the heater, and may be particularly advantageous in the case of induction-based heating in which the induction element is substantially provided on a plane adjacent to the plane of the portion of the cartridge interface surface provided by the heating element, due to the relative alignment and positioning of the heating element with respect to the plane of the induction element. In particular, the magnetic flux density extending perpendicular to the plane of the planar induction element is relatively increased compared to the magnetic flux extending parallel to the plane of the planar induction element. Accordingly, aspects of the present disclosure describe a relatively simple design that enables efficient heating.

[0029] As used herein, the term “delivery system” is intended to include systems that deliver at least one substance to a user, and includes non-combustion aerosol delivery systems that release compounds from aerosol-generating materials without burning the aerosol-generating materials, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials;

[0030] According to the present disclosure, a "non-combustion" aerosol delivery system is a system in which the constituent aerosol generating material (or its components) of the aerosol delivery system is not combusted or burned to facilitate the delivery of at least one substance to a user.

[0031] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as an electric non-combustible aerosol delivery system.

[0032] In some embodiments, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vaping device or an electronic nicotine delivery system (END), but it is noted that the presence of nicotine in the aerosol generating material is not a prerequisite.

[0033] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system and is also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0034] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol generating materials—one or more 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 include, for example, tobacco or non-tobacco products.

[0035] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and consumables for use with the non-combustion aerosol delivery device.

[0036] In some embodiments, the present disclosure relates to consumables comprising an aerosol-generating material and configured to be used with non-combustible aerosol-providing devices. Such consumables are referred to as articles throughout the present disclosure.

[0037] In some embodiments, a non-combustible aerosol delivery system, such as its non-combustible aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electric power source.

[0038] In some embodiments, the non-combustible aerosol delivery system may include an area for receiving consumables, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0039] In some embodiments, consumables for use with a non-combustible aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0040] In some embodiments, the material to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Appropriately, either material may comprise one or more active ingredients, one or more flavors, one or more aerosol-forming materials, and / or one or more other functional materials.

[0041] In some embodiments, the material to be delivered includes an active material.

[0042] As used herein, the active substance may be a physiologically active material that is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, health functional foods, nootropics, or psychotropic substances. The active substance may occur naturally or be obtained synthetically. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant materials.

[0043] In one embodiment, the active substance is a legally permitted recreational drug.

[0044] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0045] As is known in the present specification, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0046] The active substance may be CBD or its derivative.

[0047] As is known in this specification, the active substance may comprise or be derived from one or more plant materials or their components, derivatives, or extracts. As used herein, the term “botanical” includes any material derived from plants, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, peels, etc. Alternatively, the material may comprise an active compound naturally present in the plant material that is obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, crushed materials, strips, sheets, etc.

[0048] Examples of plant substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, cloves, cinnamon, coffee, anise seeds (anise), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcumin, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, macian, marjoram, olive, lemon balm, lemon basil, chives, carbi. Verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: Mentha arvensis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0049] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, and the plant substance is tobacco.

[0050] In some embodiments, the active substance comprises or is derived from one or more plant materials or their components, derivatives, or extracts, and the plant material is selected from eucalyptus, star anise, cocoa, and hemp.

[0051] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, and the plant substance is selected from rooibos and fennel.

[0052] In some embodiments, the substance to be delivered includes flavor.

[0053] As used herein, the terms “flavor” and “flavoring agent” refer to materials that may be used to produce a desired taste, aroma, or other somatosensory sensation in products for adult consumers, where permitted by local regulations. These are naturally occurring flavoring ingredients, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, Japanese white magnolia leaves, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise seeds (anise), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, Scotch, whisky, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, Qat, Nasoir, Betel, Shisha, Pine, Honey Essence, Rose Oil, Vanilla, Lemon Oil, Orange Oil, Orange Blossom, Cherry Blossom, Cassia, Caraway, Cognac, Jasmine, Ylang-ylang, Sage, Fennel, Wasabi, Pimento, Ginger, Coriander, Coffee, Hemp, Mint Oil from Any Species of the genus Mentha, Eucalyptus, Star Anise, Cocoa, Lemongrass, Rooibos, Flax, Ginkgo, Hazel, Hibiscus, Bay Leaf, Mate, Orange Peel, Rose, Tea, e.g. Green Tea or Black Tea, Thyme, Juniper, Elderflower, Basil, Bay Leaf, Cumin, Oregano, Paprika, Rosemary, Saffron, Lemon Peel, Mint, Beefsteak Plant, Curcuma, Cilantro, Myrtle, Cassis, Valerian, Pimento, Macian, Marjoram, Olive, Lemon Balm, Lemon Basil, Chives, Carvi, It may include verbena, tarragon, limonene, thymol, and camphene. These may be imitation, synthetic, or natural ingredients or combinations thereof.These can be in any suitable form, for example, a liquid such as oil, a solid such as powder, or a gas.

[0054] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises flavor components of cucumber, blueberry, citrus fruits, and / or red berry. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0055] In some embodiments, the flavor may include a sensory agent, which is intended to achieve a somatosensory sensation that is typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the flavor or taste nerves, and may include agents that provide a fever, cold, tingling, or numbing effect. A suitable fever agent may be vanillyl ethyl ether, but is not limited thereto, and a suitable cold agent may be eucalyptol, WS-3, but is not limited thereto.

[0056] An aerosol generating material is a material capable of generating an aerosol, for example, when heated, irradiated, or otherwise supplied with energy. An aerosol generating material may be in the form of a solid, liquid, or gel, for example, which may or may not contain active substances and / or flavoring agents. In some embodiments, the aerosol generating material may comprise an "amorphous solid," which may alternatively be referred to as a "mono-solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material capable of holding some fluid, such as a liquid, within it. In some embodiments, the aerosol generating material may comprise, for example, about 90 wt%, 95 wt%, or 100 wt% of an amorphous solid from about 50 wt%, 60 wt%, or 70 wt% of an amorphous solid.

[0057] The aerosol generating material may include one or more active substances and / or flavors, one or more aerosol forming agent materials, and optionally one or more other functional materials.

[0058] The aerosol-forming agent material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may comprise one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0059] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0060] A consumable is an article comprising or composed of an aerosol-generating material, intended to be consumed in whole or in part during use by a user. The consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater that emits heat to cause the aerosol-generating material to generate an aerosol during use. The heater may include a susceptor.

[0061] A susceptor is a material that can be heated by the penetration of a changing magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, so that the penetration of a changing magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, so that the penetration of a changing magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, so that the susceptor can be heated by both heating mechanisms. A device configured to generate a changing magnetic field is referred to herein as a magnetic field generator.

[0062] An aerosol modifier is a substance typically located downstream of the aerosol generation region and is configured to modify the generated aerosol by, for example, altering the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be provided to an aerosol modifier release component operable to selectively release the aerosol modifier.

[0063] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of flavoring agents, coloring agents, water, and carbon adsorbents. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, thread, or granules. The aerosol modifier may not include a filter material.

[0064] An aerosol generator is a device configured to generate an aerosol from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol generating material to thermal energy to form an aerosol by releasing one or more volatile substances from the aerosol generating material.

[0065] FIG. 1 is a highly schematic drawing (not scale) of an example of an aerosol / vapor delivery system (10) according to the present disclosure. The system (10) has a generally elongated shape extending along the longitudinal axis in this example and comprises two main components: a control or power component, a section or unit (20) (sometimes referred to as an aerosol / vapor delivery device), and a cartridge assembly or section (30) (sometimes referred to as a cartomizer or clearomiser) that carries an aerosolizable substrate material and acts as a vapor generating component.

[0066] The cartridge (30) comprises a reservoir (33) containing a source liquid (sometimes referred to as a liquid aerosol generating material) or other aerosolizable base material, for example, a formulation containing nicotine, for example, a liquid or gel, for which an aerosol is to be generated, for example, containing nicotine. For example, the source liquid may contain about 1 to 3% nicotine and 50% glycerol, with the remainder containing roughly equal amounts of water and propylene glycol, and may also contain other components such as flavors. A nicotine-free source liquid may also be used, for example, to deliver flavors. A solid base (not shown), for example, a tobacco or part of other flavoring element through which vapor generated from the liquid passes, may also be included. The cartridge (30) is configured to supply liquid from the reservoir (33) to a heating element (34).

[0067] The reservoir (33) takes the form of a storage tank, which is a container or receptacle in which the source liquid can be stored so that the source liquid can move and flow freely within the boundaries of the tank. In the case of a consumable cartridge, the reservoir (33) may be sealed after filling during manufacturing so that it can be disposed of after the source liquid is consumed, or, if not, may have an inlet port or other opening to allow the user to add new source liquid. In some examples, the cartridge (30) also includes a heating element (34) (sometimes called a heater) for generating an aerosol by vaporizing the source liquid stored in the reservoir tank (33). In some examples, the heating element (34) is intended for heating via induction, which will be described further below. In the example illustrated in FIG. 1, the heating element (34) is a susceptor (in examples where the heating element is a susceptor, the heating element may be called a susceptor heater, a susceptor heating element, or a susceptor).

[0068] A liquid transfer or delivery array (sometimes referred to as a liquid transfer element or liquid delivery element), such as a wick or other porous element (35), may be provided to transfer source liquid from a reservoir (33) to a heater (34). The wick (35) may have one or more parts located inside the reservoir (33) or may otherwise be in fluid communication with the liquid inside the reservoir (33), thereby absorbing the source liquid and transferring it by wicking or capillary action to other parts of the wick (35) adjacent to or in contact with the heater (34). By this, the liquid is heated and vaporized, replaced by a new source liquid from the reservoir, and transferred to the heater (34) by the wick (35). The wick may be conceived as a bridge, path, or conduit between the reservoir (33) and the heater (34) to transfer or deliver liquid from the reservoir to the heater. Terms including conduit, liquid conduit, liquid transport path, liquid delivery path, liquid transport mechanism or element, and liquid delivery mechanism or element may all be used interchangeably in this specification to refer to a wick or a corresponding component or structure.

[0069] A combination of a heater and a wick (or similar) is sometimes referred to as an atomizer or atomizer assembly, and a reservoir containing the source liquid and the atomizer may collectively be referred to as an aerosol source. Other terms may include a liquid transfer assembly or a liquid transport assembly, and in the current context, these terms may be used interchangeably to refer to a vapor generating element (vapor generator) and a wicking or similar component or structure (liquid transport element) that transfers or transports the liquid obtained from the reservoir to the vapor generator for vapor / aerosol generation. Various designs are possible, in which case the parts may be arranged differently compared to the highly schematic representation in FIG. 1.

[0070] In some examples, the wick (35) may be a completely separate element from the heater (34). In some other examples, the heater (34) may be configured to be porous so as to directly perform at least part of the wicking function (e.g., metallic mesh or foam). For example, the heating element (34) may include a capillary structure configured to absorb a liquid aerosol generating substrate through wicking action.

[0071] In some examples, the vapor generating element (i.e., the heating element (34)) is an induction heating susceptor element operated by induction heating to heat and vaporize the aerosol generating material. In other examples, the vapor generating element (i.e., the heating element (34)) is heated by resistance heating (e.g., by generating heat by passing an electric current through a resistance wire, path, or track) to heat and vaporize the aerosol generating material. Thus, generally, an atomizer can be considered as one or more elements that embody the functionality of a vapor generating or vaporizing element capable of generating vapor from a source liquid delivered to the vapor generating or vaporizing element, and as a liquid transfer or delivery element capable of delivering or transferring liquid from a reservoir or similar liquid reservoir to the vapor generating element by wicking action / capillary force. The atomizer is typically a component of the cartridge of a vapor generating system. In some designs, liquid may be dispensed directly from the reservoir onto the vapor generating element without a separate wicking or capillary element. Embodiments of the present disclosure are applicable to all such configurations consistent with the examples and descriptions of this specification.

[0072] The liquid delivery element (35) may comprise any suitable wicking material. For example, the liquid delivery element (35) may be manufactured from fibers that are grouped, bundled, wadded, woven, or non-woven into a fabric or fibrous mass, wherein intersticees exist between adjacent fibers to provide a capillary effect for absorbency and wicking. Examples of fibrous materials include cotton (including organic cotton), ceramic fibers, and silica fibers. Other suitable materials are not excluded and will be obvious to those skilled in the art. In some examples (as an alternative to fiber-based materials), the liquid delivery element (35) comprises a solid porous element, such as a porous ceramic material or a porous foam. For example, a porous ceramic material comprises a network of fine pores or interstices that can provide a wicking ability to support capillary action, absorb liquid from a reservoir, and transfer it to the vicinity of a heater for vaporization.

[0073] Returning to FIG. 1, the cartridge (30) comprises a housing (36) defining a mouthpiece or a portion of a mouthpiece having an opening or air outlet (12) through which a user can inhale an aerosol generated by a heating element (34). In these examples, the outer surface of the housing (36) may be shaped to accommodate the user's lips so that the user can more easily form a seal around the air outlet (12) with their mouth. In other examples (not shown), the cartridge (30) may not include or otherwise define a mouthpiece. Instead, in some examples, a mouthpiece may be connected to the cartridge (30), or the cartridge (30) may be received within a cavity of the control unit (20) (e.g., defined by the induction assembly (40)) so that the cartridge (30) provides a mouthpiece or is completely surrounded by the control unit (20) attached to the mouthpiece.

[0074] A power component or control unit (20) (sometimes referred to as a device, device part or control part because it typically includes a control circuit part) includes a power supply unit (25), such as a cell or battery, which may be rechargeable and is intended to provide power to the electrical components of the system (10), particularly to apply power to an induction element or working coil (42) (described in more detail below) to induction heat a susceptor heating element (34) or to apply current through the resistance path of a resistance heating element (34).

[0075] Additionally, there is a controller (28), such as a printed circuit board and / or other electronic devices or circuits, for controlling the aerosol delivery system (10) overall. In some examples, the control electronic device / circuit (28) operates an induction element (42) using power from a power supply (25) in response to a signal indicating that steam is needed, for example, that a user presses a button (not shown), or in response to a signal from an air pressure sensor or air flow sensor (not shown) detecting inhalation to the system (10), and during inhalation, air is introduced through one or more air inlets (14) (e.g., provided at the junction between the control unit (20) and the cartridge (30)).

[0076] When the induction element (42) is activated, the induction element (42) induction heats the heating element (34) to a suitable temperature, thereby vaporizing the source liquid delivered from the reservoir (33) by the liquid delivery element (35) to produce an aerosol, which is then inhaled by the user through the opening (12) of the mouthpiece of the cartridge housing (36). The aerosol is transported from the aerosol source to the mouthpiece outlet (12) along one or more air channels (e.g., see arrows shown in FIG. 1) that define an air path (16) connecting the air inlet (14) to the aerosol source and connecting the aerosol source to the air outlet when the user inhales through the air outlet (12).

[0077] In some examples, the control unit (20) includes a frame or support structure (22) (sometimes referred to as a device frame or support) configured to support, hold, or position various components of the control unit (20), including a power supply unit (25) and a control circuit unit (28). The frame (22) may also support other components not illustrated, such as a wired connection port for charging (and optionally, communication) and a PCB, user interface elements (e.g., buttons, LEDs, display screens, haptic feedback units), and / or wireless communication components. The frame (22) may be provided by a single component or may include a plurality of frame components combined to form the frame (22).

[0078] In some examples, the control unit (20) includes an outer housing (24) and / or an end cap (26). For example, the outer housing (24) may be a tubular structure or a wrap configured to accommodate the components of the control unit (20). For example, a frame (22) including a power supply unit (25) and a control circuit (28) may be inserted into the outer housing (24), or the outer housing (24) may be provided around the outside of the frame (22). In some examples, an end cap (26) is provided at one end of the outer housing (24) (e.g., after insertion of the frame (22) including the power supply unit (25) and the control circuit (28)) to seal the outer housing (24) (e.g., to protect the components inside the outer housing (24) from the ingress of water and dust).

[0079] The induction element or work coil (42) may be provided as part of an induction assembly (40) comprising a support structure or housing (44) configured to position or accommodate the induction element or work coil (42) (i.e., the support structure (44) supports the induction element (42). In some examples, the induction assembly (40) is formed by integrally molding the support structure (44) around the induction work element (42), whereas in other examples, the support structure (44) provides a scaffolding to which the induction work element is attached or fixed.

[0080] In some examples, the support structure (44) provides a portion of the control unit interface surface. In some examples, the induction assembly (40) includes a barrier layer that provides a portion of the control unit interface surface (49). In some examples, the barrier layer includes a coating on the surface of the induction element or a coating provided on the surface of the support structure (44). The barrier layer may be configured to prevent or reduce corrosion or damage to components of the control unit (20), such as the induction element (42).

[0081] In some examples, the induction assembly (40) includes a ferrite shield (48), such as a film, foil, or sheet, which may be held in place by a support structure (44). In some examples, the ferrite shield (48) is positioned near the induction element (42) on the opposite side of the induction element (42) with respect to the control unit interface surface (49). For example, the ferrite shield may be inserted into or embedded within the support structure (44), or provided on the lower surface of the support structure (44). The ferrite shield (48) may be used to suppress magnetic flux from the induction element (42) toward the shield when power is supplied to the induction element (42).

[0082] In some examples, the induction assembly (40) is a fixed or permanent component of the control unit (20). For example, the support structure (44) may be formed integrally with the frame (22) of the control unit (20). In other examples, the induction assembly (40) and the control unit (20) are separate connectable parts that can be separated from each other by separation in a direction parallel to the longitudinal axis of the aerosol delivery system (10). For example, the components (20, 40) are joined together when the system (10) is in use by cooperating engagement elements (e.g., screws or bayonet fittings) that provide mechanical and electrical connectivity between the power section (20) and the induction assembly (40). Electrical connectivity may be required to provide electrical power to the induction element (42) when the control circuit section (28) determines that power should be supplied to the induction element (42). The control circuit is configured to control the power supply to at least the induction element, and the control circuit is configured to drive the induction element to induce a current flow in the susceptor to induce heating of the susceptor, thereby vaporizing a portion of the aerosol generating substrate near the susceptor.

[0083] The use of a replaceable induction assembly (40) not only improves the ease of replacing the induction assembly (40) in the event of damage or wear, but also enables the user to replace the induction assembly with a different induction assembly having an alternative configuration to operate with a different heating element (34) array (e.g., provided by a cartridge (30) having a different configuration), thereby enabling customization of the system (10).

[0084] In some examples, the induction assembly (40) may seal one end of the outer housing (24) (e.g., to protect components inside the outer housing (24) from the ingress of water and dust). For example, the induction assembly (40) may be provided to the outer housing (24) at the opposite end of the end having the end cap (26). The induction assembly (40) may be connected to the frame (22) and / or the outer housing (24) in such a way that a liquid seal is formed to prevent liquid from flowing into the cavity formed by the outer housing (24), the end cap (26), and the induction assembly (40). Alternatively, in some examples, the control unit includes a second end cap that is fixed to the outer housing (24) and / or the frame (22) between the frame (22) and the induction assembly (40). In some of these examples, the second end cap may be configured to facilitate attachment of the induction assembly (40) to the control unit (20).

[0085] The control unit (power section) (20) and the cartridge (cartridge assembly) (30) are separate connectable parts that can be separated from each other by separation in a direction parallel to the longitudinal axis of the aerosol delivery system (10). In some examples, the components (20, 30) are joined together when the system (10) is in use by cooperative interlocking elements (e.g., screws or bayonet fittings) that provide mechanical connectivity (and electrical connectivity in some examples) between the power section (20) and the cartridge assembly (30). For example, a part of the outer housing (24) may be an interlocking element (not shown) configured to engage with a corresponding interlocking part (not shown) of the cartridge (30) provided by a part of the cartridge housing (36).

[0086] In some other examples, the induction assembly (40) may facilitate a connection between the control unit (20) and the cartridge (30). For example, the induction assembly (40) and the cartridge (30) may include cooperative interlocking elements (e.g., screws or bayonet fittings) that provide mechanical (and optionally electrical) connectivity between the induction assembly (40) and the cartridge (30) to indirectly connect the cartridge (30) to the control unit (20) through the induction assembly (40) (including electrical connectivity if necessary).

[0087] In systems using induction heating, if parts requiring electric power are not located in the cartridge (30), electrical connectivity may be omitted in the connection between the cartridge (30) and the control unit (20).

[0088] In some examples, the cartridge (30) and the induction assembly (40) are shaped such that (e.g., the cartridge housing (36) and the induction support structure (44), respectively) when connected, the heating element (34) is appropriately exposed to the flux generated by the induction element (42) for the purpose of generating current flow in the material of the heater. For example, the heating element (34) may be configured to provide at least a portion of the cartridge interface surface (39), the induction assembly (40) may be configured to provide at least a portion of the control unit interface surface (49), and the induction element (42) is provided near the control unit interface surface (49). In these examples, the cartridge interface surface (39) is adjacent to the control unit interface surface when the cartridge and the control unit are connected via an interface, thereby providing the induction element (42) in close proximity to the heating element (34). Induction heating arrays are discussed further below.

[0089] In some examples, the heating element (34) includes a flat surface that provides at least a portion of the cartridge interface surface (39). For example, the heating element (34) is a flat element such as a sheet of material, or the heating element (34) is a block having a flat surface on one side.

[0090] As described above, aspects of the present disclosure relate to induction heating. This is a process in which an electrically conductive item, typically made of metal, is heated by electromagnetic induction through eddy currents flowing within the item to generate heat. An induction element (42) (e.g., a working coil) acts as an electromagnet when a high-frequency alternating current from an oscillator passes through it, which generates a magnetic field. When a conductive item (i.e., a susceptor) is placed within the line flux of the magnetic field, the magnetic field penetrates the item and induces electric eddy currents. The electric eddy currents flow within the item and generate heat according to the flow of current against the electrical resistance of the item through Joule heating, in the same way that heat is generated in a resistive electric heating element by a direct current supply.

[0091] An attractive feature of induction heating is that it does not require electrical connections to conductive items; instead, the prerequisite is that sufficient magnetic flux density be generated within the area occupied by the item. In the context of vapor delivery systems where heat generation is required near a liquid, this is beneficial because it allows for more effective separation of the liquid and the electric current. Assuming that no other items requiring electric power are placed in the atomizer, no electrical connection is required between the cartridge and the power section, and a more effective liquid barrier can be provided by the atomizer walls, thereby reducing the possibility of leakage.

[0092] Induction heating is effective for the direct heating of electrically conductive items as described above, but it can also be used to indirectly heat non-conductive items. In a vapor delivery system, it is necessary to provide heat to the liquid within the porous wicking part of the atomizer to cause vaporization. In the case of indirect heating via induction, the electrically conductive item is placed adjacent to or in contact with the item requiring heating, and between the working coil and the item to be heated. The working coil directly heats the conductive item by induction heating, and heat is transferred to the non-conductive item by thermal radiation or thermal conduction. In this arrangement, the conductive item is referred to as a susceptor. Thus, in the atomizer, the heating component may be provided by an electrically conductive material (typically metal) used as an induction susceptor to transfer thermal energy to the liquid adjacent to the atomizer (e.g., held by the wick (35) and / or the heating element (34) itself).

[0093] The susceptor can be usefully formed from a suitable material that is electrically resistive / conductive, that is, capable of carrying electric current. This causes the heater to increase in temperature by being exposed to a magnetic field generated by a high-frequency alternating current in a working coil, which induces eddy currents in the heater material through inductive effects as noted above.

[0094] In some examples, the heating element (34) comprises a flat element, such as a sheet of suitable material, that is dimensioned and shaped to be suitable for making a heater. The flat element, such as a sheet, essentially provides a (first) flat surface on one side of the flat element and a second flat surface on the opposite side of the flat element. In some examples, the flat element may be a flat flat element.

[0095] In some examples, the planar element may be a flat planar element. In some of these examples, a susceptor in the form of a flat planar element is offset from the plane of the inductive element (42) and positioned parallel to that plane (e.g., each of these provides a plane parallel to a pair of parallel and adjacent planes). A portion of the planar element forming a heating element (34) offset from the plane of the inductive element (42) and parallel to that plane will be exposed to a magnetic field generated by a high-frequency alternating current within the inductive element (42). Without being bound by theory, this magnetic field will typically be strongest toward the center of the plane of the inductive element (42) in the case of a spirally wound two-dimensional coil. Thus, a portion of the heating element (34) offset and parallel to the plane of the inductive element (42) will be heated more than a portion of the heating element (34) that is additionally or alternatively offset or laterally displaced relative to the plane of the inductive element (42).

[0096] In some examples, a heating element (34) formed from a flat element such as a sheet may be curved or bent into a non-flat shape (the heating element (34) no longer occupies a single plane). The curvature may be formed by rolling or folding. In some examples, by curving or bending the heating element (34), the heating element (34) is configured to provide a nearly or substantially flat surface (rather than a flat surface) that includes a curvature that causes the flat surface to deviate from a single plane. The surfaces are considered nearly or substantially flat surfaces because the curvature of the flat surface is relatively small. For example, the curvature of the surface may be up to 10 degrees with respect to the abstract origin of the circle located opposite the plane of the inductive element (42) to the heating element (34) (in contrast to the separation between the susceptor and the plane element being up to 2 mm; the separation between the susceptor and the abstract origin being more than several cm, so that the surface of the susceptor is substantially flat with respect to the plane of the inductive element). In some examples, the inductive element (42) suitable for use with the susceptor heating element (34) may be curved similarly to the heating element (34), which may serve to increase the magnetic flux toward the middle of the heating element (34).

[0097] An element suitable for the susceptor heating element (34) is an electrically conductive material having sufficient resistance to enable heating by inductive effects through induced eddy currents. In some examples, the heating element (34) is provided by a flat element such as a sheet. For example, the heating element (34) is a sheet or foil of a metal material, and suitable metals include mild steel, ferritic stainless steel, aluminum, nickel, cupronickel, nichrome (nickel-chrome alloy), and alloys of these materials. In some examples, the sheet may be a laminate of layers of two or more materials.

[0098] The sheet thickness can be balanced with the requirement to provide a sufficient volume of resistive material to provide sufficient heating (recall that in some examples, the amount of material is reduced by perforations). Thus, in some examples, the susceptor includes planar elements, and the planar elements have a thickness in a range of one or more of 20 µm to 70 µm, 30 µm to 60 µm, and 40 µm to 55 µm. These values ​​may be the total thickness of the sheet including any supporting elements or coatings. If the thickness is insufficient, the heater may lack sufficient structural integrity, but this can be compensated for by additional components (e.g., supporting components).

[0099] In some examples, the planar element for the heater (34) has a simple rectangular or elliptical shape or profile. In other examples, the planar element for the heater (34) may have an alternative shape, such as a non-rectangular polygonal shape, or a circular or elliptical shape. This may be particularly useful when heating is intended to be concentrated in specific zones or parts within the cartridge (30).

[0100] In some of these examples where the heating element (34) is a susceptor, the planar element providing the heating element (34) may be provided in a shape corresponding to the regions where a relatively large magnetic flux is incident from the planar element.

[0101] In some other examples, the heating element (34) is not provided by a flat element (i.e., defined by two relatively large dimensions and a relatively small thickness), but instead is provided by a block element having a thickness similar in size to the two dimensions defining the flat surface of the heating element (34).

[0102] In some examples, the element or block is formed of a suitable electrically conductive material having sufficient resistance to enable heating by inductive effects through induced eddy currents. For example, the susceptor heating element (34) may include a material capable of induction heating, such as wire wool or mesh (e.g., (ferritic) stainless steel mesh), or a metal foam formed into a suitable shape (e.g., nickel foam or cupronickel foam).

[0103] In some other examples, an element or block formed from a base material on which a resistive track can be printed. For example, the base material may be a ceramic material or something similar.

[0104] In contrast to the planar element, the block (provided, e.g., by stainless steel mesh or nickel foam) may have a thickness ranging from 0.1 to 3 mm. In some examples, the stainless steel mesh or nickel foam may have a thickness ranging from 0.2 to 1 mm. In some examples, the stainless steel mesh or nickel foam may have a thickness ranging from 0.25 to 0.6 mm. The thicknesses extend perpendicularly to or away from the planar surface defining the cartridge interface surface.

[0105] In some examples, the block element for the heater (34) has a simple rectangular shape (e.g., a flat slab). In some examples, the block may be formed into a specific configuration (e.g., by curving the surface of the shape). In other examples, the block element may have an alternative shape, such as a circular or elliptical disc shape, having the thickness described above. A suitable block element provides a surface that is substantially flat by one side of the block element (e.g., a surface that provides part of the cartridge interface surface (39)).

[0106] In some of these examples where the heating element (34) is a susceptor, the block element may be configured in a shape corresponding to the regions where a relatively large magnetic flux is incident from the planar element. In some examples, the suitable block element may be formed by pressing a steel mesh into the required shape or by forming a nickel foam within a mold having the required shape.

[0107] In some examples, when the heating element is a resistance heating element, the heating element may include a substrate sheet provided with a resistive track. In some examples, the substrate sheet has a thickness in a range of one or more of 20 μm to 70 μm, 30 μm to 60 μm, and 40 μm to 55 μm.

[0108] In some examples, the heating element (34) (sometimes called the heater (34)) includes a plurality of apertures extending through the heating element (34). These apertures may be referred to as perforations or holes. In some examples, the plurality of perforations may be holes cut or punched through the material of the heating element (34) formed from a flat element (e.g., a sheet of material). Each hole is small relative to the total external surface area of ​​the heating element (34) (e.g., the flat surface of the sheet). In some examples, the holes are relatively densely packed and uniformly distributed across the surface of the heating element (34) so ​​that many holes are included. The holes may be, for example, circular, elongated, or slotted. The purpose of the holes is to allow the generated vapor to escape more easily into the aerosol chamber so that it is collected by the airflow through the aerosol chamber from the atomizer (e.g., wick and susceptor). For example, when the liquid in the wick (35) in the atomizer is vaporized by heat from the heater (34), the generated vapor can flow outward through the perforations into the free space of the air path (16) adjacent to the heater (34).

[0109] When designing the heater (34), it may be necessary to strike a balance between the increased ease of steam flow provided by additional perforations and the reduced amount of heater material available for heating. Thus, the optimal total area of ​​the perforations can be considered in relation to the area of ​​the heater material that generates heat and provides heat for vaporization. If the total heater material area without holes is defined, the range of the total area occupied by the perforations may be, for example, about 5% to 30% of the total heater material area, for example, about 20%. In any case, it is useful that the total area of ​​the perforations does not exceed about 50% due to manufacturing limitations. Furthermore, too large an open area (total area of ​​the perforations) can lead to poor induction coupling when induction heating is used, whereas too small an open area makes it difficult for the generated steam to escape from the wick (35).

[0110] In some examples, the number density of multiple openings increases or decreases along the width (and / or length) from the edges of the planar surface toward the center of the planar surface. In other words, the number density of multiple openings increases from the peripheral edges of the planar surface of the heating element (34) toward the center of the planar surface of the heating element (34).

[0111] In some examples, the density of multiple openings changes from the peripheral edge of part of the cartridge interface surface (39) toward the center of part of the cartridge interface surface (39). In some examples, the density of multiple openings increases from the peripheral edge of part of the cartridge interface surface (39) toward the center of part of the cartridge interface surface (39).

[0112] Although not illustrated, in some examples, the cartridge (30) includes a removable cover adjacent to a portion of the cartridge interface surface (39). The removable cover is removed before connecting the cartridge (30) to the control unit (20). The removable cover may cover the surface of the heating element (34) and, in some examples, may include protrusions that block a plurality of openings. The removable cover may prevent or suppress leakage from the reservoir (30) and may be formed of a material that is non-reactive with the liquid aerosol generating substrate, such as silicone.

[0113] In some examples, the heating element (34) is shaped to provide an opening for a portion of the air path (16). For example, the heating element (34) may include an opening configured to accommodate a tube that defines a portion of the air path (16) leading to the mouse end outlet (12). In some examples, the opening is oriented toward or centered on the center of the portion of the cartridge interface surface (39) defined by the heating element (34).

[0114] In some examples, the wick (35) comprises a material capable of induction heating, such as stainless steel mesh or nickel foam. The wick (35) formed from the material capable of induction heating may also provide a heater (34) component (e.g., a combined wick-heater atomizer) or may be added to the heater (34) (e.g., a wick portion of an atomizer formed by the wick (35) and the heater (34)). When the wick (35) is placed within a magnetic flux, the magnetic field penetrates the item and induces electric eddy currents. The electric eddy currents flow within the item and generate heat according to the current flow against the item's electrical resistance through Joule heating, in the same way that heat is generated in a resistive electric heating element by a direct current supply. In some examples, particularly when the wick (35) is used in conjunction with a separate susceptor heating element (34), the wick (35) may contribute to the heating of the liquid and may retain residual heat or latent heat between puffs, which may serve to reduce the amount of energy or time required to heat the susceptor heating element (34) to the vaporization temperature in subsequent puffs. In particular, the wick (35) may have a large mass compared to the susceptor heating element (34), which serves to store latent heat, whereas the relatively low mass of the susceptor heating element (34) enables rapid heating of the susceptor heating element (34).

[0115] In some examples, the stainless steel mesh or nickel foam providing the wick (35) has a shape corresponding to the heating element (34). For example, the wick (35) and the heating element (34) may include abutting surfaces configured to ensure proper contact between the wick (35) and the heating element (34). For example, the wick (35) may include a rectangular shape having the same length and width as the heating element (34). If the heating element (34) is a curved planar element, the wick (35) may be optionally manipulated into a specific configuration (e.g., by bending the surface of the shape).

[0116] In other examples, the planar element may have an alternative shape, such as a circular or elliptical shape. This may be particularly useful when heating is intended to be concentrated in specific zones or parts within the cartridge (30). In some examples, the wick (35) may or may not have a corresponding shape.

[0117] In some examples, the wick (35) can assist in positioning the heating element (34) by applying a holding force to the heating element (34) caused by the compression of the wick (35) between the heater (35) and the element of the housing (36) in contact with the wick (35).

[0118] In some examples, a liquid transfer element (35) (sometimes called a wick) provides liquid to a second heater surface (e.g., an abutting surface) on the opposite side of the heating element (34) to the cartridge interface surface (39). In some examples, the liquid may be supplied to the heating element (34) through the liquid transfer element (35), and then, when the liquid vaporizes, the liquid may pass through the heating element (34) from the second heater surface to the cartridge interface surface (39) provided by the heating element (34) (e.g., by one or more openings extending through the heating element (34).

[0119] Returning to FIG. 1 in more detail, in the illustrated example, the induction assembly (40) includes an induction element (42) operable to induce a current flow in the heating element (34) of the cartridge (30) to induce heating the heating element (34), thereby aerosolizing a portion of the aerosol generating substrate near the heating element (34). The induction assembly provides at least a portion of the control unit interface surface (49), and the induction element (42) is provided near the control unit interface surface (49). For example, the induction element (42) is defined by a plane parallel to and adjacent to the plane of the control unit interface surface (49), or defines the control unit interface surface (49).

[0120] The cartridge (30) and the induction assembly (40) are shaped such that the cartridge interface surface (39) and the control unit interface surface (49) provided by the induction assembly (40) are parallel and adjacent to each other, and an air gap is provided between the two surfaces through which the generated aerosol joins the air path (16).

[0121] In particular, in the examples according to FIG. 1, the induction element (42) is provided in the form of a planar induction element, and the induction coil is formed in substantially one plane with respect to an axis. In examples such as those according to FIG. 1, the axis on which the planar induction element is formed is parallel to the longitudinal axis of the system (10). In some examples, the planar induction element (42) and the control unit interface surface (49) provided near it are formed in a plane perpendicular to the longitudinal extension of the system (10).

[0122] In some examples, the planar induction element (42) is formed by a resistance wire, such as nickel or cupronickel wire, configured or arranged in a flat spiral. In some examples, the induction element is a Litz coil. In some examples, the resistance wire providing the planar induction element (42) is provided to a support structure (44) that serves to maintain the resistance wire in a specific shape (e.g., a two-dimensional spiral). In some of these examples, the resistance wire may be embedded in the support structure. In other examples, the resistance wire providing the planar induction element (42) is substantially self-supporting in that the resistance wire can support the orientation and configuration of the resistance wire at an anchor location (i.e., the location where the resistance wire engages with the support structure (44)). For example, the resistance wire may be a material that is suitablely rigid (e.g., a suitablely thick wire) to maintain its configuration throughout continuous use.

[0123] In some examples, a planar induction element (42) may be printed or deposited on a portion of a substrate or support structure (44) configured to be inserted into a recess (47) when the cartridge (30) is attached to the induction assembly (40) and / or device (20). In some examples, a laser is used to activate the surface of the support structure (44), and the support structure (44) may comprise a thermoplastic material such as polyetheretherketone (PEEK) which can be doped with a metal inorganic compound. The laser creates one or more laser-activated regions on the support structure (44), and these regions may be further metallized to form one or more conductive layers, for example, of copper, using an electroless plating process. For example, an inductor coil (42) may be deposited on the support structure (44) to form a helical inductor coil (42). However, other embodiments are considered in which the inductor coil (42) may be formed on the support structure (44) to have a different configuration.

[0124] As described above, by utilizing a laser direct structuring process, a planar inductive element (42) is formed by printing or depositing a conductive layer on a support structure (44), thereby forming an inductive element (42) that is integrated with or within the support structure (44). This advantageously reduces the size of the required support structure (44) compared to the support structure (44) suitable for holding the resistance wire that provides the planar inductive element (42), thus allowing the inductive assembly (40) to be provided in a more compact arrangement.

[0125] In some examples, the planar induction element (42) is a planar induction coil. For example, the planar induction element (42) is a flat spiral coil (sometimes called a pancake coil). A flat coil means that the coil is wound spirally in a two-dimensional plane from the outermost point of the spiral to the innermost point of the spiral (which does not necessarily have to be at the geometric center of the spiral). In some examples, the coil may protrude to some extent out of the two-dimensional plane and may be considered to be folded or bent. In these examples, the flat spiral coil is substantially flat in that the degree of bending or folding out of the plane is relatively small and preferably less than 5 degrees out of the plane. In other examples, the spiral coil does not protrude out of the two-dimensional plane of the spiral configuration except by the three-dimensional thickness of the element providing the spiral coil (e.g., wire thickness or deposition thickness).

[0126] In some examples, the helical coil increases regularly or consistently from the most central point to the most outer point (e.g., a constant radial increase per change in angle) and can be considered substantially circular helical coils. In some other examples, the helical coil has a substantially elliptical or irregular shape, caused by varying the radial increase as a function of the change in angle from the axis and the distance from the most central point to the most outer point, for example.

[0127] In the example of FIG. 1, a portion of the induction assembly (40) containing the induction element (42) is a portion of the support structure (44) or housing of the induction assembly (40). This portion of the support structure (44) may have a planar shape corresponding to or related to the plane of the planar induction coil. The support structure (44) may be defined by first and second planar surfaces on each side of the planar induction coil (42) (i.e., intersecting the axis on which the planar induction coil is formed) and also by one or more peripheral surfaces radially outward from the spiral (i.e., not intersecting the axis on which the spiral coil is formed). The support structure (44) may surround the planar induction element (42) to provide a protective housing for the planar induction element (42) and / or to support or maintain the position of the induction element (42) within the induction assembly (40). In some other examples, not illustrated, at least a portion of the planar induction element (42) may not be covered by the support structure (44). In these examples, the planar induction element (42) may be exposed to ambient air.

[0128] At least a portion of the susceptor heating element (34) (i.e., the portion providing the cartridge interface surface (39)) is provided near the surface of the induction assembly (40) proximal to the induction element (42) (i.e., the control unit interface surface (49)). The portion of the susceptor heating element (34) defining the cartridge interface surface (39) is provided parallel and adjacent to the plane of the planar induction element (42) (and to the control unit interface surface (49)).

[0129] For the purpose of generating a current flow in the material of a heater, the susceptor heating element (34) is provided with a (planar) susceptor heating element (34) that defines an adjacent cartridge interface surface (39) parallel to the plane of the planar induction element (42), so that the susceptor heating element (34) is properly exposed to the line flux generated by the induction element (42) provided on or adjacent to the control unit interface surface (49), thereby causing the susceptor heating element (34) to respond to the magnetic field generated by the planar induction element (42). In this way, the susceptor heating element (34) responds to the magnetic field generated by the planar induction element (42). If the susceptor heating element (34) is positioned such that the separation of the susceptor heating element (34) from the planar induction element (42) is minimized, the line flux experienced by the susceptor heating element (34) may be higher, and the heating effect may be more efficient.

[0130] The distance separating the susceptor heating element (34) from the inductive element (42) is sometimes referred to as the coupling distance. Without being bound by theory, the susceptor heating element (34) and the inductive element (42) effectively form a pair capable of transferring energy to the susceptor heating element (34) when the inductive element (42) is inductively coupled to the susceptor heating element (34) and current is applied to the inductive element (42). The coupling distance relates to the distance over which energy is transferred from the inductive element (42) to the susceptor heating element (34). The further the susceptor heating element (34) is (i.e., the greater the coupling distance), the greater the energy loss. In some examples, to reduce energy loss by a suitable rate, the coupling distance is in the range of less than 2 mm. In some examples, the coupling distance is in the range of less than 1.5 mm. In some examples, the coupling distance is in the range of less than 1 mm.

[0131] The coupling distance can alternatively be described by an offset distance related to the distance separating the planar surface from the planar induction coil (e.g., the difference between abstract parallel planes related to the cartridge interface surface (39) and the planar induction coil (42)). In some examples, the cartridge interface surface (39) defined by the susceptor heating element (34) is offset from the planar induction element (42) by an offset distance in the range of less than 2 mm. In some examples, the cartridge interface surface (39) is offset from the planar induction element (42) by an offset distance in the range of less than 1.5 mm. In some examples, the cartridge interface surface (39) is offset from the planar induction element (42) by an offset distance in the range of less than 1 mm.

[0132] As illustrated in FIG. 1, in some examples, the aerosol delivery system (10) includes an air path (16) partially defined by the volume between the heating element (34) and the control unit interface surface (49) (e.g., defined by the induction assembly (40)). The separation between the cartridge interface surface (39) and the control unit interface surface (49) is set at least partially by the width or size of the portion of the air path (16) formed between the cartridge interface surface (39) and the control unit interface surface (49), and the air path (16) in this area of ​​the system (10) needs to be sized to enable sufficient air flow. In some examples, the separation between the cartridge interface surface (39) and the control unit interface surface (49) is in the range of greater than 0.5 mm. In some examples, the separation between the cartridge interface surface (39) and the control unit interface surface (49) is in the range of greater than 1 mm. The separation between the cartridge interface surface (39) and the control unit interface surface (49) can sometimes be referred to as the thickness of the air path (16).

[0133] In some examples, the separation distance between the cartridge interface surface (39) and the control unit interface surface (49) is in the range of 0.3 mm to 2.5 mm. In some examples, the separation distance between the cartridge interface surface (39) and the control unit interface surface (49) is in the range of 0.5 mm to 1.5 mm. The minimum distance depends on the requirements for air flow resistance through the gap between the cartridge interface surface (39) and the control unit interface surface (49), while the maximum distance depends on ensuring that the coupling distance is not too large (thereby reducing the efficiency of induction heating). In some examples, the thickness of any blocking layer and / or support structure (44) separating the induction element (42) from the cartridge interface surface (39) is 1 mm or less.

[0134] Although not illustrated in FIG. 1, in some examples, the cartridge (30) includes a spacer (or a plurality of spacers) protruding outward from the cartridge interface surface (39). In some examples, the gap or volume between the cartridge interface surface (39) and the control unit interface surface (49) is maintained by the presence of one or more spacers (or protrusions) extending from the plane defining the cartridge interface surface (39) and / or the control interface surface (49). Each spacer (or protrusion) may have a height (outside the plane of the relevant surface) corresponding to the required air gap so that the spacer contacts the opposite surface and maintains a gap between the surfaces corresponding to the height of the spacer. In some examples, one or more spacers are provided around at least a portion of the periphery of the cartridge interface surface (39) and / or the control unit interface surface (49).

[0135] In some examples where the heating element (34) is a susceptor heating element (34), the requirements of the aerosol path (16) and the coupling distance need to be balanced when determining the size setting and positioning of various items. In some examples, the coupling distance is in the range of 0.75 mm to 2 mm, the separation (thickness of the air path (16)) between the cartridge interface surface (39) and the control unit interface surface (49) is in the range of greater than 0.5 mm to 1.5 mm, and the separation between the cartridge interface surface (39) and the control unit interface surface (49) is less than or equal to the coupling distance. In some examples, the coupling distance may be equal to or substantially equal to the separation between the cartridge interface surface (39) and the control unit interface surface (49). For example, there may be no additional features between the cartridge interface surface (39) and the control unit interface surface (49) (e.g., the support structure (44) may not include the inductive element (42), and the inductive element (42) may instead extend from the support structure (44). In some other examples, the coupling distance may be smaller than the separation between the cartridge interface surface (39) and the control unit interface surface (49) due to the presence of a protective layer or a housing layer (e.g., provided by the support structure (44) to protect the inductive element (42)).

[0136] In some examples where the heating element (34) is either a resistance heating element or a susceptor heating element (34), the provision of an air path (16), partially defined by the volume between the heating element (34) and the control unit interface surface (49), provides a system (10) that includes a large vaporization surface (e.g., corresponding to a portion of the cartridge interface surface (39) provided by the heating element (34)) that enables significant aerosol generation, while including a relatively simple system to manufacture in which the heating element (34) provides the base portion (or surface) of the cartridge (30).

[0137] The design of FIG. 1 is merely an exemplary arrangement, and various parts and features may be distributed differently between the power section (20) and the cartridge assembly section (30), and other components and elements may be included. The two sections may be connected end-to-end in a longitudinal configuration as in FIG. 1, or connected in a different configuration such as a parallel arrangement. The system may or may not have a cylindrical shape overall and / or a longitudinal shape overall. Any one or both of the sections or components may be intended to be discarded and replaced when depleted (e.g., when the reservoir is empty or the battery is discharged), or may be intended for multiple uses made possible by actions such as refilling the reservoir and recharging the battery. In other examples, the system (10) may be a monolithic unit in that parts of the control unit (20) (e.g., including the induction assembly (40)) and the cartridge (30) are contained in a single housing and cannot be separated. The embodiments and examples of the present disclosure are applicable to any of these configurations and other configurations recognized by those skilled in the art.

[0138] FIG. 2 is a cross-sectional view through an example of an aerosol delivery system (10) according to the present disclosure, wherein the cross section intersects the support structure or housing (44) of the induction assembly (40) with the outer housing (24) of the control unit (20). The housing (44) includes a recess (47) for the induction element (42). Aspects of the support structure (44) (and related components for use with the support structure) can be understood as described in relation to FIG. 1.

[0139] The outer housing (24) surrounds the induction assembly support structure (44). In some examples, as in the example of FIG. 2, both the outer housing (24) and the support structure (44) have a rounded rectangular outer periphery shape having at least one pair of substantially parallel sides and rounded corners connecting the parallel sides. It will be understood that the outer housing (24) and the support structure (44) may have different outer periphery shapes, such as circular or elliptical shapes.

[0140] The recess (47) comprises a pair of opposing spiral recesses (47) each configured to accommodate a spiral coil of a single induction element (42). In particular, in some examples, the induction assembly comprises a pair of adjacent opposing spiral coils within a single plane. That is, the induction element (42) comprises a first portion comprising a first spiral coil and a second portion connected to the first portion comprising a second spiral coil that is spirally wound inwardly in the opposite direction to the first spiral coil. In some examples, each of the spiral recesses comprises a plurality of parallel sections provided toward the center of the support structure (44), and the first spiral recess is adjacent to the second spiral recess. This can advantageously enable heating concentrated at the center of each opposing spiral coil (i.e., due to the concentration of magnetic flux at the center).

[0141] The first helical recess is provided in the first part (e.g., half) of the support structure (44), and the second helical recess is provided in the adjacent second part (e.g., half) of the support structure (44). Providing two helical recesses may be advantageous for systems having an elongated cross-section (e.g., a non-circular ellipse, such as a substantially elliptical shape where the major axis is 2-3 times the minor axis). In other examples, the recess (47) may include a single helical recess.

[0142] The induction assembly (40) is created by providing a planar induction element (42) (e.g., a wire that can be wound spirally) suitable for the recess (47). In other examples, where the induction element (42) is not provided by a pair of connected spiral coils, it will be understood that the insertion part (45) may have an alternative recess (47) suitable for accommodating an alternative induction element (42).

[0143] The recess (47) of the support structure (44) may be open so as to be visible from the surface of the support structure (44), or the recess (47) may be inside the housing (44) (i.e., to encapsulate the inductive element (42). In some examples, the recess (47) is provided on the surface of the support structure (44) that provides the control unit interface surface (49) (e.g., the cross-section shown in FIG. 2 may depict the control unit interface surface (49)). In some examples where the recess (47) is provided on the surface of the support structure (44) that provides the control unit interface surface (49), the inductive element (42) provided in the recess (47) defines a part of the control unit interface surface (49).

[0144] The inductive element (42) can be provided by a resistance wire or a conductive track, as discussed above in relation to FIG. 1.

[0145] FIG. 3 is a cross-sectional view through an example of an additional aerosol delivery system (10) according to the present disclosure, wherein the cross section intersects the support structure or housing (44) of the induction assembly (40) and the outer housing (24). Aspects of the support (44) (and related components for use with the support structure) may be understood as described in relation to FIG. 1 or FIG. 2.

[0146] In contrast to the example of FIG. 2, the exemplary induction assembly (40) of FIG. 3 includes a first recess (471) and a second recess (472), each configured to accommodate an induction element (42) (e.g., a separate, independent induction element). As such, the induction assembly (40) of FIG. 3 can be considered to provide a two-induction element system.

[0147] In some examples, as illustrated in FIG. 3, the first recess (471) and the second recess (472) are spiral recesses that rotate in opposite directions. For example, the first recess includes a first spiral recess, and the second recess includes a second spiral recess that is spirally wound inward in the opposite direction to the first spiral coil.

[0148] The induction assembly (40) is created by providing planar induction elements (42) (e.g., wires that can be wound spirally) suitable for each of the recesses (47). Thus, in some examples, the induction assembly comprises a first induction element and a second induction element. The first induction element is provided near a first portion of the control unit interface surface and is operable to induce current flow in the first portion of the heating element of the cartridge to induce heating of the first portion of the heating element, thereby aerosolizing a portion of the aerosol generating substrate near the first portion of the heating element. The second induction element is provided near a second portion of the control unit interface surface and is operable to induce current flow in the second portion of the heating element of the cartridge to induce heating of the second portion of the heating element, thereby aerosolizing a portion of the aerosol generating substrate near the second portion of the heating element. In some examples, the first induction element and the second induction element comprise coils that rotate in opposite directions. In some examples, the first and second induction elements are a pair of adjacent coils that rotate in opposite directions within a single plane.

[0149] In some examples, a system (10) comprising two inductive elements (42) is advantageous in that each inductive element (42) can be powered separately, and importantly, power can be supplied to each inductive element (42) alternately. For example, power can be supplied to the first inductive element (42) of the first concave portion (471) for a certain period of time, and then power can be supplied to the second inductive element (42) of the second concave portion (472) for a certain period of time (e.g., alternately at a frequency of about 50 Hz).

[0150] In some examples, in a system (10) comprising two induction elements (42), one of the induction elements (42) may be operated without operating the other induction element (42). Thus, the operated induction element (42) may heat an adjacent portion of the heating element (42), while the portion of the heating element adjacent to the other induction element (42) is substantially not heated (e.g., not heated to a vaporization temperature).

[0151] In some examples, the cartridge (30) comprises a first reservoir for a first liquid aerosol generating substrate and is configured to supply liquid from the first reservoir to a first part of a heating element (34), and the cartridge (30) comprises a second reservoir for a second liquid aerosol generating substrate and is configured to supply liquid from the second reservoir to a second part of a heating element (34). In some examples, the cartridge (30) comprises a first liquid aerosol generating substrate and a second liquid aerosol generating substrate, wherein the first liquid aerosol generating substrate is different from the second liquid aerosol generating substrate.

[0152] Advantageously, if the cartridge (30) comprises first and second reservoirs each having an aerosol generating substrate (which may be different from each other), selectively operating one or both of the inducing elements (42) allows the aerosol generated by the system (10) to be changed. For example, in some examples where the aerosol generating substrates of the different reservoirs are different, the flavor may be selected and / or the active substance may be introduced by aerosolizing the reservoir having the corresponding flavor or active substance. In other examples where the aerosol generating substrates of the different reservoirs are the same, the intensity or concentration of the aerosol generated by the system (10) may be changed.

[0153] FIG. 4 is a cross-sectional view of the cartridge interface surface (39) of the cartridge (30) according to the present disclosure. Aspects of the cartridge (30) not described in detail below may be understood as described in relation to FIG. 1.

[0154] The cartridge interface surface (39) of FIG. 4 is defined by a susceptor heating element (34) providing a base (e.g., bottom plate) of the cartridge (30) and a part of a housing (36) surrounding the periphery of the susceptor heating element (34). In some examples, the susceptor heating element (34) may be a planar element comprising a planar surface that defines at least a part of the cartridge interface surface (39).

[0155] A portion of the housing (36) includes a rim or edge of the cartridge interface surface (39). In some examples, a heating element (34) may be held by the rim as part of the cartridge (30). For example, the rim may include a shelf or ledge that contacts the heating element (34) to hold the heating element (34) within the cartridge (30).

[0156] The rim comprises a series of spacers (366) (or protrusions) and air flow gaps (368) (or openings). The spacers of the rim are configured (or otherwise provided) to engage with corresponding portions of the control unit interface surface (49) (not shown) so that when the cartridge (30) is connected to the induction assembly (40) of the control unit (20), a void is formed between the cartridge interface surface (39) and the control unit interface surface (49). In some examples, there are at least two spacers (366). In some examples, two of the at least two spacers (366) are provided on opposite sides of the heating element (34) that provide the cartridge interface surface (39). In some examples, the spacers (366) are additionally configured to extend inward over the surface of the heating element (34) to hold the heating element (34) as part of the cartridge (30).

[0157] Air flow gaps (368) are provided around the rim of the housing (36) between the spacers (366) so that air can flow into the gap between the cartridge interface surface (39) and the control unit interface surface (49) through the air flow gaps (368). Each air flow gap (368) is formed between each pair of spacers (366). In some examples, there may be at least two air flow gaps (368).

[0158] The cartridge (30) includes an air flow passage (364) extending through a heating element (34). The air flow passage (364) provides part of the air path (16) of the system (10). The heating element (34) includes an opening that allows air and / or aerosol to flow into the air flow passage (364) from the gap between the cartridge interface surface (39) and the control unit interface surface (49). The central passage may extend from the gap to the mouse end of the cartridge (30) (e.g., the outlet (12)). In this way, air may flow into the system (10) through the inlet (14), toward and through the air flow gaps (368), and flow into the air flow passage (364) and out of the mouse end outlet (12) across the surface of the heating element (34) that provides part of the cartridge interface surface (39).

[0159] The opening of the heating element may be a circular opening (or cutout) or may have a different shape, such as elongated slots (e.g., rectangular or elliptical). In some examples, the air flow passage (364) may be considered a central passage (364) because it is provided on the surface of the heating element (34) and at the center of the cartridge (30). In some other examples, although not illustrated, the passage is not a central passage (i.e., not located at the center of the cartridge (30)) but is instead displaced to one side of the cartridge (30).

[0160] The wall defining the air flow passage through the cartridge (30) may also define the boundary of the reservoir (33). In some of these examples, the reservoir (33) may be provided by an annular cavity between the wall defining the air flow passage (364) and the outer wall of the housing (36). The reservoir (33) may be filled with a liquid transfer element (35) configured to hold the liquid aerosol generating material in contact with the heating element (34).

[0161] In some examples, as illustrated in FIG. 4, the heating element (34) includes a plurality of openings (345) extending through the heating element (34). The openings (345) may be referred to as perforations or holes. In some examples, the plurality of perforations (345) may be holes cut or punched through the material of the heating element (34) (e.g., a sheet of susceptor material). Each hole (345) is small relative to the total external surface area of ​​the heating element (34) (e.g., a plane of the sheet). The holes (345) may be, for example, circular, elongated, or slotted. The purpose of the holes (345) is to allow the generated vapor to escape more easily into the aerosol chamber so that it is collected by the airflow through the aerosol chamber from the atomizer (e.g., wick and susceptor). For example, when the liquid in the wick (35) inside the atomizer is vaporized by heat from the heater (34), the generated vapor can flow outward through the perforations into the free space of the air path (16) adjacent to the heater (34).

[0162] In some examples, the holes (345) are relatively densely packed in one or more regions of the heating element (34). For example, the holes (345) may be provided in regions where air flow is primarily expected or in regions corresponding to a relatively larger magnetic flux generated by the induction element (42). In some examples, if the induction element (42) comprises two helical sections (e.g., separate coils or a single pair of interconnected coils rotating in opposite directions), the openings (345) may be provided near the approximate center of each helical section. In some examples, the openings (345) may be provided between the rim of the housing (36) and the air flow passage (364) along a relatively wider axis of the cartridge (30). In some examples, the grouped openings (345) are fanned out from the air flow passage (364) toward the air flow gap (368).

[0163] FIG. 5 is a cross-sectional view of the cartridge interface surface (39) of the cartridge (30) according to the present disclosure. Aspects of the cartridge (30) not described in detail below may be understood as described in relation to FIG. 1.

[0164] In contrast to the exemplary cartridge of FIG. 4, the exemplary cartridge of FIG. 5 includes a resistive track (62) provided on the surface of the heating element (34) (the surface providing the cartridge interface surface (39)). The heating element (34) of FIG. 5 is a resistive heating element (34) configured to be heated by passing an electric current through the resistive track (62) to generate thermal energy. In other words, the temperature of the resistive heating element (34) is increased by the passage of an electric current through the resistive track (62) to generate heat. While heat is generated by the resistive track (62), the substrate of the heating element (34) provided with the resistive track (62) may also be heated by heat conduction from the resistive track. Generally, the substrate for the resistive heating element comprises a material that is a good thermal conductor and a poor electrical conductor, and can also be heated to a high temperature without damage, such as a ceramic material.

[0165] In some examples, the resistive track (62) comprises a single conductive path extending between two electrical contacts (64). The electrical contacts (64) may be provided at both ends of the resistive track (62) and are each configured to provide electrical contact with each electrode of a suitable control unit (20) when the cartridge (30) is attached to the control unit (20). For example, the control unit (20) may include a pair of electrodes protruding from the control unit interface surface (49) to engage with the electrical contacts (64). In some examples, the electrodes are configured to have a height equal to the height of the spacer (366). In some examples, the resistive track (62) may be formed of a conductive material (e.g., copper) by printing or depositing a conductive layer on the substrate material of the heating element (34).

[0166] In some examples, the resistance track (62) is configured as a sinuous or meandering path, and openings (345) are provided near the resistance track (62). Resistance heating of the part of the heating element (34) provided with the openings (345) allows the aerosol generating material adjacent to the heating element (34) to be aerosolized into the air path (16) through the openings (345).

[0167] FIG. 6 is a highly schematic drawing (not scale) of an example of a mouthpiece (50), a cartridge (30), and an induction assembly (40) for use in an aerosol / vapor delivery system (10) according to the present disclosure. The cartridge (30) differs from the cartridge (30) shown in FIG. 1 in that the cartridge (30) is configured to be received within a cavity (51) that is at least partially defined by a separate mouthpiece component (50) (referred to herein as mouthpiece (50)). The heating element (34), liquid transfer element (35), reservoir (33) of the cartridge (30), and induction assembly (40) of FIG. 6 are as described in relation to FIG. 1 and will not be described again in detail. Alternative embodiments of the cartridge (30) and induction assembly (40) suitable for use with the mouthpiece (50) as disclosed in FIG. 6 may include aspects described in relation to FIG. 2 through 4. Additionally, although not illustrated, in some examples, a cartridge (30) having a resistance heating element (34) as shown in FIG. 5 can be used with a mouthpiece (50) as described in detail below, in combination with a control unit (20) comprising a resistive track (62) and a pair of electrodes for creating a resistive circuit instead of an induction assembly (40).

[0168] The cartridge (30) of FIG. 6 may be called a pod or capsule and is configured to be received within a cavity (51) or void partially defined by the mouthpiece (50). For example, the housing (36) of the cartridge (30) is not configured to define the shape of the mouthpiece, but instead is configured to define a structure that can be received within the system (10) by the mouthpiece (50) and can accommodate components such as a reservoir (33), a susceptor (34), and a liquid transfer element (35).

[0169] In the example of FIG. 6, the cavity (51) for receiving the cartridge (30) is defined by an induction assembly (40) providing a control unit interface surface (49) at one end and by a mouthpiece (50) at the opposite end. The periphery of the cavity (51) is defined by an outer housing (24) including a periphery wall extending from the control unit (20). In use, the cartridge (30) is received within the cavity (51) defined by the outer housing (24) and the induction assembly (40) such that the cartridge interface surface (39) is adjacent to the control unit interface surface (49), and then the control unit end of the mouthpiece (50) is inserted into the outer housing (24) to hold the cartridge (30) in place. In this system (10), the mouthpiece (50) can form an interference fit with the outer housing (24) which holds the mouthpiece (50) in contact with the outer housing (24). This attachment can be considered a push-fit mechanism. When a user wants to replace the cartridge (30), the user can pull the mouthpiece (50) from the outer housing (24) to allow the cartridge (30) to be extracted (i.e., apply force to overcome the interference fit).

[0170] In some examples, the cavity (51) corresponds to the external shape defined by the cartridge (30) but has a shape and size larger than the external shape defined by the cartridge (30) (e.g., slightly larger, such as 1% larger). This allows the cartridge (30) to be inserted or placed within the cavity (51), so that the cartridge (30) is held within the cavity (51). In some examples, the size of the cartridge (30) and the size of the cavity (51) may be substantially similar so that a press fit is formed between the housing (52) defining the cavity (51) and the housing (36) defining the cartridge (30).

[0171] As depicted in FIG. 6, the housing (36) may be a body having a central air flow passage (364) extending between two openings on opposite end faces of the body. The air flow passage (364) provides part of the air path (16) of the system (10). A heating element (34) provides an opening at one end of the air flow passage (364). The opening may be circular or of a different shape, such as elongated slots (e.g., rectangular or elliptical).

[0172] The walls of the air flow passage (364) further define the inner walls of the reservoir (33). The reservoir (33) is provided by a cavity (51) (e.g., an annular cavity) defined by the housing (36) and the walls of the air flow passage (364). The cartridge (30) includes a liquid transfer element (35) provided within the reservoir (33). In contrast to FIG. 1, the liquid transfer element (35) fills the entire reservoir (33). It will be understood that in other examples having a mouthpiece (50) as described in relation to FIG. 6, the liquid transfer element (35) may include only the section adjacent to the heating element (34) and may not fill the entire reservoir (33).

[0173] As also depicted in FIG. 6, in some examples, the support structure (44) of the induction assembly (40) includes attachment features (441) configured to facilitate the connection of the housing (44) to a control unit (20) having corresponding attachment features (221). In these examples, the induction assembly (40) is detachably attached to the control unit (20). In some examples, the attachment features (441) allow the induction assembly (40) to be reversibly connected to the control unit (20) so that the induction assembly (40) can be removed and replaced without damaging the control unit (20) or the induction assembly (40). This allows the control unit (20) to be used with different types of cartridges having different susceptor arrays. In some other examples, the induction assembly (40) is an integral component of the control unit (20), and the attachment features (441) and the corresponding attachment features (221) may be omitted (e.g., the housing (44) may be formed integrally with the housing of the control unit), or the attachment features (441) may be configured to provide a permanent attachment that is irreversible (i.e., cannot be disconnected).

[0174] FIG. 7 is a highly schematic drawing (not scale) of an example of a mouthpiece (50), a cartridge (30), and an induction assembly (40) for use in an aerosol / vapor delivery system (10) according to the present disclosure. Similar to the exemplary cartridge (30) of FIG. 6, the exemplary cartridge (30) of FIG. 7 is configured to be received within a separate mouthpiece component (50) (referred to herein as mouthpiece (50)).

[0175] In contrast to FIG. 6, the housing (52) of the mouthpiece (50) comprises two parts: a first upper, downstream or mouth end part (52) and a second lower, upstream or device end part (54). The cavity (51) may be formed by one or both of the upper and lower parts (52, 54).

[0176] In the example of FIG. 7, the cavity (51) is an internal space or volume defined by the upper and lower housing parts (52, 54), and the upper housing part (52) also defines the external shape of the mouthpiece (50). For example, the upper housing part (52) defines the outlet (12) of the air path (16) that the user can inhale. In some examples, the upper and lower housing parts (52, 54) are formed of metal or plastic material (for example, the housing may be formed by a plastic injection molding process). Additionally, the mouthpiece (50) of FIG. 7 includes an opening mechanism (56) and a locking mechanism (58).

[0177] The opening mechanism (56) is configured to enable movement of the first part (52) relative to the second part (54), or vice versa. In some examples, the opening mechanism (56) is a hinge or a flexible connector. If the opening mechanism (56) is a hinge, the opening mechanism (56) may enable rotation of the first part (52) relative to the second part (54). In some examples, rotation may be about an axis perpendicular to the longitudinal axis of the system (10), and in some other examples, rotation may be about an axis parallel to the longitudinal axis of the system (10).

[0178] The opening mechanism (56) allows the mouthpiece (50) to move between a first configuration in which the cavity (51) is at least partially exposed so that the cartridge (30) can be inserted and / or removed, and a second configuration in which the cavity (51) is substantially closed (except through openings for the air path (16)) to hold and / or protect the cartridge (30) provided within the cavity (51). The first configuration may be referred to as an open or accessible configuration because the cavity (51) is open and accessible to the user, and the second configuration may be referred to as a closed or inaccessible configuration because the cavity (51) is closed and inaccessible to the user.

[0179] As such, in some examples, the mouthpiece includes an opening mechanism configured to allow the mouthpiece to move between a first configuration and a second configuration, wherein the cavity in the first configuration is at least partially exposed to allow a cartridge to be inserted and / or removed, and the second configuration is configured to hold a cartridge provided within the cavity.

[0180] Advantageously, the opening mechanism (56) allows the user to open the cavity (51) without completely disconnecting the first part (52) from the second part (54), thereby improving user accessibility because the user does not need to hold each part (52, 54) separately while inserting or removing the cartridge (30) from the cavity (51). However, in some other examples, the opening mechanism (56) may not be included, and instead, it will be understood that the first part (52) and the second part (54) may be completely separated from each other when changing the mouthpiece configuration from the second configuration to the first configuration.

[0181] The connecting mechanism (58) serves to hold the first part (52) in contact with the second part (54) of the housing. For example, the connecting mechanism (58) may be a latch or locking device that prevents or inhibits the movement of the first part (52) relative to the second part (54), or vice versa. The connecting mechanism (58) is configured to prevent or inhibit the mouthpiece (50) from moving from a closed configuration to an open configuration in order to prevent the cartridge (30) from unintentionally moving out of the cavity (51) before the user intends to remove the cartridge (30).

[0182] In some examples, a connecting mechanism (58) is provided on one or both of the first part (52) and the second part (54). For example, the connecting mechanism (58) may include a corresponding component configured to engage with each of the first and second parts (52, 54) to prevent or inhibit movement of the first and second parts (52, 54) relative to each other. In some examples, the connecting mechanism (58) includes a mechanical mechanism comprising a latch or clip on one of the first part (52) and the second part (54), and a corresponding component (e.g., a second clip or ridge) on the other of the first part (52) and the second part (54) for holding the latch or clip. In some examples, the connecting mechanism (58) includes a first magnet in a first part (52) and a second magnet in a second part (54) (which exerts an attractive force on the first magnet), and the two magnets generate a force that must be overcome to move the first part (52) relative to the second part (54).

[0183] In some examples, the connection mechanism (58) is user-operable so that the user can interact directly with the connection mechanism (58) to prevent the connection mechanism (58) from holding the mouthpiece in a second configuration. In other words, the connection mechanism (58) is user-operable so that the user can interact directly with the connection mechanism (58) to allow the first part (52) to move relative to the second part (54) (e.g., the user can move or bend the latch in a position relative to the corresponding clip, or apply force to overcome the attractive force between the two magnets).

[0184] In some examples, the connection mechanism (58) is electronically controlled (e.g., electrically operated by the control circuit (28)). For example, although not illustrated, at least part of the connection mechanism (58) may be electrically connected to the control circuit (28) and may be operable by the control circuit (28) (e.g., in response to electrical signals) to activate or deactivate the connection mechanism (58). In some examples, the connection mechanism (58) may include an electromagnet and a permanent magnet, the electromagnet being configured to generate a magnetic field when current is supplied through the electromagnet, which creates an attractive force between the permanent magnet and the electromagnet. In some examples, the connection mechanism (58) includes an actuator movable in response to an electrical signal to engage with a latch or similar (such latch and actuator may be positioned out of sight to the user when the mouthpiece (50) is in a second configuration).

[0185] Advantageously, the connection mechanism (58) can be used to delay the user when the user attempts to replace the cartridge (30). For example, when the heating element (34) is heated to a high temperature. In particular, if the user heats the heating element (34) multiple times in a short period of time (e.g., 10 puffs per minute), the elements of the cartridge (30) (particularly the heating element (34) and components near the heating element (34)) may become hot. If the user removes the cartridge (30) immediately after puffing, the user (or items nearby, such as their clothing or a table) may be burned.

[0186] The provision of the connection mechanism (58) delays the user's immediate access to the cartridge (30) and instead allows heat (thermal energy) to be dissipated across the entire cartridge (30) and surrounding elements of the system (10). It will be understood that even if the connection mechanism (58) is a simple mechanical mechanism such as a latch, it can still delay the user's access to the cartridge by a few seconds (e.g., at least 2 to 3 seconds). In some examples, where the connection mechanism (58) is electronically controlled, the control circuit (28) may implement a timer that prevents the connection mechanism (58) from being disengaged for a certain period of time after the most recent activation of the inductive element (42) (e.g., the time is in the range of more than 3 seconds, preferably more than 5 seconds). In some examples, the time may be fixed, whereas in other examples, the time may be calculated based on the system usage up to the last puff (e.g., the time may be longer due to increased usage before the last activation).

[0187] In some examples, although not illustrated, the lower portion (54) may not be a component of the mouthpiece (50). Instead, in these examples, the induction assembly (40) or device (20) defines or otherwise provides at least a portion of the cavity (51) for the cartridge (30) (e.g., at least the induction assembly (40) or device (20) may define the end surface of the cavity together with the remaining surfaces defined by a single mouthpiece housing component). In these examples, the connection mechanism (58) and / or opening mechanism (56) as described above may be provided by the induction assembly (40) or device (20). For example, the mouthpiece (50) may be connected to the induction assembly (40) or device (20) (e.g., the housing (24) of the device (20)) by a hinge (opening mechanism (56)). As such, in some examples, the mouthpiece (50) includes at least one component of the connection mechanism, and the connection mechanism is configured to hold the mouthpiece as a second component.

[0188] Additionally, in some examples, a connection mechanism (58) as described above is provided to directly connect the cartridge (30) to the control unit (20) and / or the induction assembly (40) without the presence of a separate mouthpiece (50). For example, the connection mechanism (58) can engage or lock the cartridge (30) to the control unit (20) and / or the induction assembly (40) to prevent the cartridge from being unintentionally disconnected.

[0189] FIG. 8 is a flowchart illustrating a method (100) for generating an aerosol from an aerosol generating substrate in an aerosol delivery system (10) according to the present disclosure. The aerosol delivery system (10) comprises a cartridge (30) and a control unit (20), wherein the cartridge (30) comprises a heating element (34) providing at least a portion of a cartridge interface surface (39); and the control unit (20) comprises a control unit interface surface (49). The system (10) and its components (e.g., an induction assembly (40), a cartridge (30), and a control unit (20)) may be as described in connection with any one of FIGS. 1 to 7 and will not be described again in detail.

[0190] The method (100) begins with a first step (110) of connecting the cartridge (30) to the control unit (20) through an interface. The cartridge interface surface (39) is adjacent to the control unit interface surface (49) when the cartridge (30) and the control unit (20) are connected through the interface. The cartridge interface surface (39) and the control unit interface surface (49) can be defined by substantially parallel planes, with an air gap provided between them to form part of the air path (16) of the system (10) extending from the inlet (14) to the outlet (12).

[0191] In some examples, the heating element (34) includes a susceptor, and the control unit (20) includes an induction assembly (40) that provides a portion of the control unit interface surface (49). The induction assembly (40) includes an induction element (42) operable to induce a current flow in the heating element (34) of the cartridge (30) to induce heating of the heating element (34), thereby aerosolizing a portion of the aerosol generating substrate near the heating element (34). The induction element (42) is provided near the control unit interface surface (49) so that the induction element (42) is also adjacent to the susceptor (34) because the susceptor (34) provides at least a portion of the cartridge interface surface (39) (e.g., all of which define planes parallel to each other).

[0192] The guiding element (42) may be a planar guiding element defined by a plane. The plane defining the planar guiding element (38) means the plane on which the planar guiding element (38) is substantially arranged (e.g., in the case of a two-dimensional helical coil, the plane of the helix). The planar guiding element (42) is offset from the susceptor (34) in a direction perpendicular to the plane (e.g., to form an air gap). The planar surface of the susceptor (34) is provided in a direction displaced perpendicular to the plane of the planar guiding element (42) (e.g., in the case of a two-dimensional helical coil, the susceptor (34) may be displaced from the helical coil (42) with respect to an axis passing through the center point or origin of the helical coil (42)). In some examples, the offset distance is equal to the distance separating the cartridge interface surface (39) and the control unit interface surface (49) (e.g., because the induction element (42) is provided on the surface of the induction assembly (40)), whereas in other examples, the offset distance is greater than the distance separating the cartridge interface surface (39) and the control unit interface surface (49) (e.g., because a support structure (44) or blocking layer defining the control unit interface surface (49) is provided between the induction element (42) and the heating element (34).

[0193] In some examples, the heating element (34) is a resistive heating element (34) comprising a resistive track (62) provided on a portion of the cartridge interface surface (39). In these examples, the control unit (20) includes a pair of electrical contacts (e.g., electrodes) configured to provide an electrical connection to each portion (64) of the resistive track (62) when the cartridge (30) and the control unit (20) are connected via an interface.

[0194] In some examples, the method (100) continues to the step (120) of heating the heating element to a first temperature by passing an electric current through the heating element to vaporize a portion of the aerosol generating substrate near the heating element (34).

[0195] In some examples where the control unit (20) includes an induction element and the heating element (34) is a susceptor, heating the heating element by flowing current through the heating element and thereby vaporizing a portion of the aerosol generating substrate near the heating element (34) involves driving the induction element (42) to induce current flow in the heating element to induce heating of the heating element (34). In these examples, the induction element (42) may be driven to heat the susceptor heating element (34) above the vaporization temperature of the aerosol generating component of the aerosol generating substrate (e.g., liquid from the reservoir (33)).

[0196] In some examples, the control unit (20) comprises a pair of electrical contacts for forming an electrical circuit with the resistive track of the heating element, heating the heating element by flowing current through the heating element and thereby vaporizing a portion of the aerosol generating substrate near the heating element (34) involves supplying current through the resistive track between each portion of the resistive track. In these examples, current may be supplied through the resistive track (62) to heat the resistive heating element (34) above the vaporization temperature of the aerosol generating component of the aerosol generating substrate (e.g., liquid from the reservoir (33)).

[0197] The temperature at which the heating element (34) is driven to vaporize a portion of the aerosol generating substrate near the heating element (34) may be considered as a first temperature, a vaporization temperature, or an aerosolization temperature. In some examples, the first temperature is in the range of 150°C to 300°C. In some examples, the first temperature is in the range of 190°C to 220°C.

[0198] In some examples, step (120) is triggered by user input. For example, the user may engage with a user input element. For example, the user may interact with a user-operable element such as a button, or the user may inhale the system (e.g., through the outlet (12)) to trigger a puff sensor. In addition to the user input element being a user-operable element such as a button or a puff sensor, the user input element may also be any sensor capable of identifying user interaction (e.g., a capacitive sensor, a motion sensor, or an optical sensor). The user input element may be configured to transmit a signal to the control circuit (28) indicating that user input has occurred, and the control circuit (28) may trigger step (120) (i.e., drive the planar induction element (42)). For example, when a user inhales through the outlet (12), the puff sensor transmits a signal identifying user input corresponding to the inhalation (e.g., a signal identifying a pressure drop) to the control circuit, and the control circuit (28) causes current to flow to the heating element (34) (e.g., by applying current directly or through induction) in response to a signal indicating that the user is interacting with the user input element.

[0199] In some examples, the system (10) includes a temperature sensor for measuring the temperature of the heating element (34). The temperature sensor may be configured to measure a value representing the temperature of the heating element (34) rather than directly measuring the heating element (34). For example, a suitable temperature sensor may determine the temperature of the heating element (34) based on the resistance of an element near the heating element (34) (e.g., a thermocouple near the heating element (34)). In some examples, an inductive element (42) may be used to measure the temperature of the heating element (34) based on the strength and frequency of the inductive coupling between the susceptor and the inductive element (42). Measurements or signals related to the temperature of the heating element (34) (directly or indirectly) may be transmitted to the control circuit (28) and may be used to control how the inductive element (42) is driven (i.e., to achieve or maintain the temperature).

[0200] In some examples, the method ends after current is passed through the heating element (34) to heat the heating element (34) to a first temperature. For example, the control circuit (28) may stop the current from passing through the heating element (34) after a time corresponding to the user's puff and / or in response to a predicted amount of aerosol generated (e.g., based on knowledge of the energy input to the system and the energy required to vaporize the aerosol generating material, or based on predetermined data such as a lookup table for a specific system (10) configuration). In some examples, the control circuit (28) may stop the current from passing through the heating element (34) by stopping the driving element (42) to induce current flow in the heating element (34) to induce heating the heating element (34) to a first temperature.

[0201] In some examples, the method ends after current is passed through the heating element (34) to heat the heating element (34) to a first temperature for a fixed time. In some examples, the fixed time may be a time in the range of 1.5 to 5 seconds. In some examples, the fixed time may be a time in the range of 2.5 to 4 seconds.

[0202] In some examples, the method terminates after heating the heating element (34) to a first temperature by flowing current through it when no user input (e.g., inhalation, button pressing, or similar as described above) is provided. For example, when the user stops inhaling the system (10), the puff sensor transmits a signal indicating that the air pressure has increased, and the control circuit (28) stops flowing current (e.g., by stopping driving the induction element (42)). Alternatively, when the user stops pressing the button of the system (10), the button transmits a signal indicating that the button is not being pressed, and the control circuit (28) stops flowing current. In some examples, the control circuit (28) implements a maximum activation period even when the user continues to trigger the user input mechanism. This can prevent the system (10) from overheating, for example, if the user input element malfunctions. In some examples, the maximum activation period is a period ranging from 6 to 15 seconds. In some examples, the maximum activation period is a period ranging from 7 to 12 seconds. In some examples, the method (100) may be terminated after step (120).

[0203] In some examples, the method (100) includes an additional step (115) of passing an electric current through a heating element (34) to heat the heating element (34) to a second temperature that is lower than a first temperature and is not sufficient to vaporize a portion of the aerosol-generating substrate near the heating element (34). In other words, the second temperature is lower than the temperature required to vaporize a portion of the aerosol-generating substrate near the heating element (34). The second temperature may be considered a preheating temperature. In some examples, the second temperature is in the range of 80°C to 200°C. In some examples, the second temperature is in the range of 120°C to 170°C. The heating element (34) may be a resistance heating element or a susceptor heating element as discussed above in relation to step (120).

[0204] Thus, in some examples according to step (115), the method (100) comprises heating the heating element (34) to a first temperature by flowing current through the heating element (34) to vaporize a portion of the aerosol generating substrate near the susceptor, and the method further comprises heating the heating element (34) to a second temperature lower than the first temperature and lower than the temperature required to vaporize a portion of the aerosol generating substrate near the heating element (34).

[0205] It will be understood that the control circuit (28) can heat the heating element (34) to a specific temperature by, for example, modifying the power supplied through the planar induction element (42) or, for example, applying the power supplied through the resistive track (62). For example, the control circuit (28) can monitor the temperature of the heating element (34) by a suitable sensor (e.g., a thermocouple or based on a change in resonant frequency detectable by the planar induction element (42)) and can change the power supplied through the planar induction element (42) or the resistive track (62). For example, the control circuit (28) can supply power (to the resistive track (62) or the induction element (42)) in periodic pulses at a set frequency (e.g., 500-50 Hz) until the required temperature is reached. As long as the heating element (34) is above the required temperature, the control circuit (28) can stop supplying power during the next scheduled pulse. When the heating element (34) drops below the required temperature, the control circuit (28) can resume supplying pulses.

[0206] Providing a preheating temperature may be particularly advantageous when used with a susceptor heating element (34) formed of a high mass element, such as a block element formed of steel mesh or nickel foam, and / or when the heating element (34), such as a sheet, is formed of a wick (35) that can be inductively heated (e.g., steel mesh or nickel foam). Although such heating elements (34) and / or wicks (35) may take a relatively long time to heat due to their high mass, they can store latent heat between activations. Thus, by maintaining the heating element (34) and / or wick at a temperature higher than the ambient temperature, the time required to heat the heating element (34) to a first temperature to vaporize a portion of the aerosol generating substrate near the heating element (34) is reduced. Additionally, the high mass of the heating element (34) and / or wick (35) increases the time it takes for the temperature of the heating element (34) to return to ambient conditions, because the heating element (34) and / or wick (35) has an increased bulk heat capacity that is more difficult to dissipate to the surrounding system (10) due to a reduced external surface area to volume ratio compared to a flat element such as a thin metal sheet.

[0207] In some examples, the control circuit is configured to heat the heating element (34) to a second temperature by flowing current through the heating element (34) in response to a stimulus, and the stimulus includes one or more of a signal indicating a connection to the control unit (20) of the cartridge (30) and a signal indicating the user's intention to start a usage session.

[0208] In some examples, the stimulus may be the detection of a connection to the control unit (20) of the cartridge (30). In some examples, the control circuit (28) may determine that the cartridge (30) is already attached (i.e., currently attached) based on a measurement or sensor reading (e.g., a signal from a sensor to detect the attachment of the cartridge (30), such as an optical sensor, a signal indicating that a circuit has been formed with the resistive track (62), or a signal from the inductive element (42) indicating that an element capable of being inductively heated has moved toward the inductive element (42). In some examples, the stimulus may be the user pressing a button on the device (20) or the user taking the first puff on the device (20) (triggering this if a puff sensor is present).

[0209] The stimulus may indicate the user's intention to start a usage session (e.g., the user's intention to perform a series of puffs in the system (10) (a puff means the user inhaling from the outlet (12) of the system (10)). In some examples, the method (100) comprises (the control circuit (28)) heating the heating element (34) to a second temperature by flowing current through the heating element (34) in response to the stimulus, and the stimulus includes one or more of a signal indicating a connection to the control unit (20) of the cartridge (30) and a signal indicating the user's intention to start a usage session.

[0210] In some examples, the control circuit (28) is configured to maintain the heating element (34) at a second temperature before raising the temperature to a first temperature during activation (e.g., puff) of the device (20) by the user, and / or the control circuit (28) is configured to maintain the heating element (34) at a second temperature between activations of the device (20) by the user. In other words, the control circuit (28) is configured to maintain the heating element (34) at a second temperature before raising the temperature to a first temperature in response to a signal indicating that the user is interacting with the user input element, and / or the control circuit is configured to maintain the heating element (34) at a second temperature between signals indicating that the user is interacting with the user input element. By maintaining the temperature of the heating element (34) at a second temperature, the time required to raise the temperature to a first temperature may be reduced, thereby leading to faster generation of steam (where an aerosol generating material is present). As discussed above, user input elements may include one or more of buttons, capacitive sensors, motion sensors, optical sensors, and pressure sensors, or any other suitable input mechanism.

[0211] As such, in some examples, the method (100) includes heating the heating element (34) from a second temperature to a first temperature by flowing current through the heating element (34) in response to a signal indicating that the user is interacting with the user input element. For example, while the control circuit (28) is heating the heating element (34) to a second temperature by flowing current through the heating element (34), the user may press a button or inhale the system (10), and the control circuit (28) may switch to heating the heating element (34) from a second temperature to a first temperature by flowing current through the heating element (34).

[0212] In some examples, the control circuit (28) is configured to perform step (115) (e.g., by passing current through the heating element (34) to heat the heating element to a second temperature lower than the first temperature) after performing step (120) (passing current through the heating element to heat the heating element to a first temperature). In some examples, this is in addition to passing current through the heating element (34) before the first puff (e.g., in response to a stimulus) to heat the heating element (34) to a second temperature lower than the first temperature.

[0213] In some examples, the control circuit (28) is further configured to alternately heat the heating element (34) to a first temperature and heat the heating element (34) to a second temperature in response to receiving user input and not receiving user input, respectively. For example, when the user inhales or indicates that they are inhaling (e.g., pressing a button), the heating element (34) is heated to a first temperature, and when the user stops inhaling or stops indicating that they are inhaling (e.g., stopping pressing a button), the heating element (34) is heated to a second temperature. It will be understood that this may involve stopping the flow of current to the heating element (34) until the heating element (34) cools from the first temperature to the second temperature, and then periodically flowing current to heat the heating element to maintain the heating element (34) at the second temperature.

[0214] Thus, in some examples, the method includes maintaining the heating element (34) at a second temperature after a signal indicating that the user is interacting with the user input element is interrupted, and / or between signals indicating that the user is interacting with the user input element.

[0215] In some examples, where the method includes step (115), the method (100) additionally includes step (125) of stopping the flow of current to the heating element (34) after an inactive period. The control circuit (28) may be configured to maintain the heating element (34) at a second temperature for a certain period of time in response to stimulation, and may be configured to stop the flow of current to the heating element (34) if no input is received from the user before the time expires. In other words, in some examples, the control circuit is configured to stop the flow of current to the heating element (34) to maintain the heating element (34) at a second temperature after an inactive period. As above, the input (i.e., an action indicating activity) may be a button press or a puff (measured by a puff sensor) indicating that the user is inhaling or intends to inhale the system (10). In some examples, the inactive period is in the range of 10 seconds to 120 seconds. In some examples, the inactive period is in the range of 20 to 60 seconds. In some examples, the method (100) may be terminated after step (125).

[0216] When the method (100) is terminated, the system (10) may enter a standby mode or a low-power sleep mode. For example, after step (120) or after step (125), the control circuit (28) may enter a standby mode in which it periodically looks up user input elements for indications that the user is inhaling the device or intends to inhale (or for other interactions related to system control, such as checking battery levels, changing heater temperature, and turning off or resetting the device). In some examples, if no user input is received for a certain period of time (e.g., 5 to 10 minutes), the control circuit (28) may turn off the system (10) or place the system (10) into a low-power sleep mode.

[0217] In some examples, there is a connection mechanism (58) configured to hold a cartridge (30) as part of an aerosol delivery system (10) (e.g., as described in connection with FIG. 8). The method may additionally include engaging and disengaging the connection mechanism (58), and the connection mechanism (58) can be operated electronically (e.g., by a control circuit (28)). In some examples, the connecting mechanism (58) connects different parts of the mouthpiece (50) defining the cavity (51), or the connecting mechanism (58) connects the mouthpiece (50) to the control unit (20) and / or the induction assembly (40) (where the cavity (51) for the cartridge (30) is provided by one or more of the mouthpiece (50), the control unit (20), and the induction assembly (40), or the connecting mechanism (58) directly connects the cartridge to the control unit (20) and / or the induction assembly (40) (e.g., no separate mouthpiece (50)).

[0218] In some examples, the method (100) further comprises engaging a connection mechanism (58) configured to hold a cartridge as part of an aerosol delivery system, and disengaging the connection mechanism (not shown). By disengaging the connection mechanism, the user can remove and / or attach the cartridge (30) (e.g., by inserting the cartridge (30) into the cavity (51). By implementing such a connection mechanism (58), the risk of injury to the user or damage to the surrounding environment may be reduced because disabling or disengaging the connection mechanism may delay the user removing the cartridge for a few seconds; during that time, the heating element (34) may be cooled to a low temperature.

[0219] In some examples, the method includes the control circuit (28) engaging the connection mechanism (58) in response to the control circuit (28) determining that a cartridge is attached to the system. In some examples, the method includes the control circuit (28) engaging the connection mechanism (58) in response to receiving input from a user indicating that the connection mechanism (58) should be engaged. For example, the connection mechanism (58) may be engaged in response to a first activation of the aerosol delivery system (10).

[0220] In some examples, the method includes the control circuit (28) disengaging the connection mechanism (58) in response to receiving input from a user indicating that the connection mechanism (58) should be disengaged (e.g., a button press or a combination of button presses). In some examples, the method includes the control circuit (28) disengaging the connection mechanism (58) in response to entering a standby mode or a low-power sleep mode. In some examples, the method includes the control circuit (28) disengaging the connection mechanism (58) in response to ceasing to drive the inductive element (42) after an inactive period. In some examples, the method includes the control circuit (28) disengaging the connection mechanism (58) in response to determining that a certain amount of time has elapsed since the last activation (e.g., time since the control circuit (28) heated the susceptor to a first temperature). In some of these examples, the time since the last activation may be in the range of 2 to 10 seconds or 3 to 5 seconds. In some examples, the method includes the control circuit (28) disengaging the connection mechanism (58) in response to the heating element (34) determining that it is below a critical temperature.

[0221] Accordingly, a cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate has been described. The cartridge is configured to be connected to and disconnected from a control unit of the aerosol delivery system via an interface. The cartridge includes a heating element configured to aerosolize a portion of the aerosol generating substrate in the vicinity of the heating element, and the heating element provides at least a portion of the cartridge interface surface. The cartridge interface surface is configured to be adjacent to the control unit interface surface when the cartridge and the control unit are connected via the interface.

[0222] A mouthpiece for use in an aerosol delivery system has also been described. The mouthpiece is configured to hold a cartridge according to a first aspect within a cavity. The mouthpiece includes an outlet for the aerosol delivery system; and an opening mechanism configured to allow the mouthpiece to move between a first configuration and a second configuration. In the first configuration, the cavity is at least partially exposed to allow the cartridge to be inserted and / or removed. In the second configuration, the mouthpiece is configured to hold a cartridge provided within the cavity.

[0223] An induction assembly for use with a cartridge according to a first aspect has also been further described. The induction assembly includes an induction element operable to induce a current flow in a heating element of the cartridge to induce heating of the heating element, thereby aerosolizing a portion of an aerosol generating substrate near the heating element. The induction assembly provides at least a portion of a control unit interface surface. The induction element is provided near the control unit interface surface.

[0224] A control unit for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate has also been further described. The control unit comprises an induction assembly of a third aspect; a power supply for supplying power to an induction element; and a control circuit for controlling the power supply to the induction element. The control circuit is configured to drive the induction element to induce a current flow in a heating element to induce heating of the heating element, thereby vaporizing a portion of the aerosol generating substrate near the heating element.

[0225] An aerosol delivery system for generating an aerosol from an aerosol generating substrate was also further described. The aerosol delivery system comprises a cartridge of a first aspect and a control unit of a fourth aspect, wherein an air path is provided between the cartridge interface surface and the control unit interface surface.

[0226] A method for generating an aerosol from an aerosol generating substrate in an aerosol delivery system is also described, wherein the aerosol delivery system comprises a cartridge and a control unit, the cartridge comprises a heating element providing at least a portion of a cartridge interface surface; and the control unit comprises a control unit interface surface. The method comprises the steps of connecting the cartridge to the control unit through an interface — the cartridge interface surface is adjacent to the control unit interface surface when the cartridge and the control unit are connected through the interface — and heating the heating element by passing an electric current through the heating element to vaporize a portion of the aerosol generating substrate near the heating element.

[0227] As is known, the heating element according to the present disclosure may be a susceptor for induction heating or a resistance heater for heating a liquid aerosol generating material, as described in relation to the cartridges illustrated in FIGS. 1 and FIGS. 4 through 7. In some other examples, the heating according to the present disclosure may be used for heating alternative aerosol generating materials, such as gel aerosol generating materials (e.g., thermo-reversible gel).

[0228] In conclusion, to solve various problems and advance technology, the present disclosure illustrates various embodiments in which the claimed invention(s) may be practiced. The advantages and features of the present disclosure are merely representative samples of embodiments and are not exhaustive or / or exclusive. They are presented only to aid in understanding and teaching the claimed invention(s). The advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limitations on the present disclosure or on equivalents of the claims as defined by the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claims. Various embodiments may suitably include, be composed of, or constitute essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein, and thus it will be understood that features of dependent claims may be combined with features of independent claims in combinations other than those explicitly described in the claims. The present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

[0229] Furthermore, there is a considerable degree of flexibility in the design and configuration of the entire aerosol delivery system, which is exemplified by the various possibilities of features outlined in at least the set of provisions following this paragraph. To avoid any doubt, it will be correspondingly understood that any of the features of these provisions may be combined as needed in any combination beyond those explicitly stated in these provisions, and that the great flexibility and interchangeability in the use of such features clearly provided by this disclosure should be noted.

[0230] Clauses

[0231] Clause 1. A cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate, wherein the cartridge is configured to be connected to and disconnected from a control unit of the aerosol delivery system through an interface, and

[0232] The cartridge includes a heating element configured to aerosolize a portion of an aerosol generating substrate in the vicinity of a heating element, wherein the heating element provides at least a portion of the cartridge interface surface;

[0233] A cartridge whose cartridge interface surface is configured to be adjacent to the control unit interface surface when the cartridge and the control unit are connected through an interface.

[0234] Clause 2. A cartridge according to Clause 1, wherein the heating element comprises a flat surface that provides at least a portion of the cartridge interface surface.

[0235] Clause 3. In the cartridge of any preceding clause, the cartridge comprises a spacer protruding outwardly from the cartridge interface surface.

[0236] Clause 4. In the cartridge of Clause 3, the spacer protrudes outward from the cartridge interface surface by a distance ranging from 0.3 mm to 2 mm.

[0237] Clause 5. A cartridge of any preceding clause, wherein the heating element comprises a capillary structure configured to absorb a liquid aerosol generating substrate by wick action.

[0238] Clause 6. A cartridge of any preceding clause, wherein the heating element comprises a plurality of openings extending through the heating element.

[0239] Clause 7. In the cartridge of Clause 6, a plurality of openings are arranged in a pattern, and the density of the plurality of openings varies from the peripheral edge of a portion of the cartridge interface surface toward the center of a portion of the cartridge interface surface.

[0240] Clause 8. In the cartridge of Clause 7, the density of the plurality of openings increases from the peripheral edge of a portion of the cartridge interface surface toward the center of a portion of the cartridge interface surface.

[0241] Clause 9. In the cartridge of any preceding clause, the cartridge comprises a reservoir for a liquid aerosol generating material, and the cartridge is configured to supply liquid from the reservoir to a heating element.

[0242] Clause 10. In the cartridge of Clause 9, the cartridge comprises a liquid transfer element configured to absorb a liquid aerosol generating material toward a heating element by wick action.

[0243] Clause 11. In the cartridge of Clause 10, the liquid transfer element is formed of a susceptor material, the cartridge.

[0244] Clause 12. A cartridge according to any one of clauses 9 to 11, wherein the reservoir is a first reservoir for a first liquid aerosol generating material, the cartridge includes a second reservoir for a second liquid aerosol generating material, and the cartridge is configured to supply liquid from the second reservoir to a second part of a heating element.

[0245] Clause 13. In the cartridge of Clause 12, the cartridge comprises a first liquid aerosol generating substrate and a second liquid aerosol generating substrate, wherein the first liquid aerosol generating substrate is different from the second liquid aerosol generating substrate.

[0246] Clause 14. In a cartridge of any preceding clause, the heating element comprises a resistive track provided on the cartridge interface surface.

[0247] Clause 15. A cartridge in any one of Clauses 1 to 13, wherein the heating element comprises a susceptor.

[0248] Clause 16. In the cartridge of Clause 15, the susceptor is formed of a material having a capillary structure configured to absorb a liquid aerosol generating substrate by wicking action.

[0249] Clause 17. In the cartridge of Clause 16, the susceptor is formed from one of wire wool, mesh, or metal foam.

[0250] Clause 18. In the cartridge of Clause 17, the susceptor comprises a nickel foam or a cupronickel foam.

[0251] Clause 19. In the cartridge of Clause 18, the susceptor comprises a stainless steel mesh, the cartridge.

[0252] Clause 20. A cartridge according to any one of clauses 15 to 19, wherein the susceptor comprises a planar element, and the planar element has a thickness in a range of at least one of 20 μm to 70 μm, 30 μm to 60 μm, and 40 μm to 55 μm.

[0253] Clause 21. In the cartridge of Clause 18, the flat element comprises a sheet or foil.

[0254] Clause 22. A cartridge of Article 20 or Article 21, wherein the planar element comprises one or more of mild steel, ferritic stainless steel, aluminum, nickel, cupronickel, and nichrome.

[0255] Clause 23. In the cartridge of any preceding clause, the cartridge comprises a removable cover adjacent to a portion of the cartridge interface surface.

[0256] Clause 24. In the cartridge of any preceding clause, the cartridge is configured to provide a mouthpiece for a user to inhale an aerosol generated from an aerosol generating substrate.

[0257] Clause 25. A mouthpiece for use in an aerosol delivery system, wherein the mouthpiece is configured to hold a cartridge in a cavity in accordance with any one of provisions 1 to 23, and the mouthpiece comprises an outlet for the aerosol delivery system.

[0258] Clause 26. A mouthpiece of Clause 25, wherein the mouthpiece comprises an opening mechanism configured to allow the mouthpiece to move between a first configuration and a second configuration, wherein in the first configuration, a cavity is at least partially exposed to allow a cartridge to be inserted and / or removed, and in the second configuration, the mouthpiece is configured to hold a cartridge provided within the cavity.

[0259] Clause 27. A mouthpiece according to Clause 26, wherein the mouthpiece comprises at least one component of a connecting mechanism, and the connecting mechanism is configured to hold the mouthpiece as a second component.

[0260] Clause 28. In the mouthpiece of Clause 27, the connection mechanism is user-operable mouthpiece such that the user can directly interact with the connection mechanism to prevent the connection mechanism from holding the mouthpiece as a second component.

[0261] Clause 29. A guide assembly for use with a cartridge according to any one of Articles 1 through 24, wherein the guide assembly comprises:

[0262] An induction element operable to induce a current flow in the heating element of a cartridge to induce heating of the heating element, thereby aerosolizing a portion of the aerosol generating substrate near the heating element.

[0263] Includes,

[0264] An induction assembly that provides at least a portion of the control unit interface surface, and an induction element provided near the control unit interface surface.

[0265] Clause 30. A guidance assembly according to Clause 29, wherein the guidance assembly comprises a support structure configured to hold a guidance element.

[0266] Clause 31. In the induction assembly of Clause 30, the support structure provides a part of the control unit interface surface.

[0267] Clause 32. In the induction assembly of Clause 29 or Clause 30, the induction assembly comprises a blocking layer that provides a portion of the control unit interface surface.

[0268] Clause 33. In the induction assembly of Clause 32, the blocking layer comprises a coating on the surface of an induction element.

[0269] Clause 34. An induction assembly in any one of Clauses 29 to 33, wherein the induction element is formed of a resistance wire.

[0270] Clause 35. An inductive assembly according to any one of clauses 29 to 33, wherein the inductive element comprises one or more conductive layers deposited on a support structure.

[0271] Clause 36. An inductive assembly of Clause 35, wherein one or more conductive layers comprise a metal or a metal alloy.

[0272] Clause 37. In the inductive assembly of Clause 36, one or more conductive layers comprise copper, nickel, silver, gold, chromium, palladium, tin, aluminum, platinum, tungsten, or zinc.

[0273] Clause 38. An induction assembly according to any one of Clauses 34 to 37, wherein the induction element comprises a planar helical coil.

[0274] Clause 39. An induction assembly according to any one of Articles 34 to 37, wherein the induction element comprises a pair of adjacent coils rotating in opposite directions within a single plane.

[0275] Clause 40. In the induction assembly of Articles 29 to 39, the induction assembly comprises a ferrite shield, the ferrite shield being positioned near the induction element on the opposite side of the induction element with respect to the control unit interface surface.

[0276] Clause 41. In the induction assembly of Articles 29 to 40, the induction element is a first induction element and the induction assembly includes a second induction element;

[0277] A first induction element is provided near a first portion of the control unit interface surface, and the first induction element is operable to induce a current flow in a first portion of the heating element of the cartridge to induce heating of the first portion of the heating element, thereby aerosolizing a portion of the aerosol generating substrate near the first portion of the heating element; and

[0278] An induction assembly, wherein a second induction element is provided near a second portion of the control unit interface surface, and the second induction element induces a current flow in the second portion of the heating element of the cartridge to induce heating of the second portion of the heating element, thereby enabling aerosolization of a portion of the aerosol generating substrate near the second portion of the heating element.

[0279] Clause 42. An induction assembly in which the second induction element in the control unit of the induction assembly of Clause 41 comprises coils rotating in opposite directions.

[0280] Clause 43. As a control unit for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate, the control unit is,

[0281] An inductive assembly of any one of Clauses 29 to 42;

[0282] A power supply for supplying power to an inductive element; and

[0283] A control unit comprising a control circuit for controlling power supply to an induction element, wherein the control circuit is configured to drive the induction element to induce current flow in a heating element to induce heating of the heating element, thereby vaporizing a portion of an aerosol generating substrate near the heating element.

[0284] Clause 44. In the control unit of Clause 43, the induction assembly is a control unit that is detachably attached to the control unit.

[0285] Clause 45. A control unit according to Clause 43 or Clause 44, wherein the control circuit is configured to drive an induction element to induce current flow in the heating element to induce heating the heating element to a first temperature in order to vaporize a portion of the aerosol generating substrate near the heating element, and the control circuit is configured to drive an induction element to induce current flow in the heating element to induce heating the heating element to a second temperature lower than the first temperature and lower than the temperature required to vaporize a portion of the aerosol generating substrate near the heating element.

[0286] Clause 46. A control unit of Clause 45, wherein the second temperature is a temperature in the range of 80°C to 200°C.

[0287] Clause 47. A control unit of Clause 45 or Clause 46, wherein the control circuit is configured to drive an induction element to induce a current flow in a heating element in response to a stimulus to induce heating of the heating element to a second temperature, the stimulus comprising one or more of a signal indicating a connection to the induction assembly of the cartridge and / or the control unit, and a signal indicating a user's intention to start a usage session.

[0288] Clause 48. A control unit in any one of clauses 45 to 47, wherein the control circuit is configured to drive an induction element to induce a current flow in a heating element in response to a signal indicating that a user is interacting with a user input element, thereby inducing the heating element to heat the heating element from a second temperature to a first temperature.

[0289] Clause 49. A control unit of Clause 48, wherein the control circuit is configured to maintain a heating element at a second temperature after a signal indicating that a user is interacting with a user input element is interrupted, and / or between signals indicating that a user is interacting with a user input element.

[0290] Clause 50. A control unit according to Article 48 or Article 49, wherein the control unit comprises a user input element, and the user input element comprises one or more of a button, a capacitive sensor, a motion sensor, an optical sensor, and a pressure sensor.

[0291] Clause 51. A control unit in any one of clauses 45 to 50, wherein the control circuit is configured to stop driving the induction element to induce current flow in the heating element to maintain the heating element at a second temperature after an inactive period.

[0292] Clause 52. A control unit of Clause 51, wherein the inactive period is in the range of 10 seconds to 120 seconds.

[0293] Clause 53. As an aerosol delivery system for generating an aerosol from an aerosol generating substrate, the aerosol delivery system is,

[0294] A cartridge of Clause 24, or a cartridge of any one of Clauses 1 through 23, and optionally a mouthpiece of any one of Clauses 25 through 28; and

[0295] An aerosol delivery system comprising a control unit of any one of provisions 43 to 52, wherein an air path is provided between a cartridge interface surface and a control unit interface surface.

[0296] Clause 54. An aerosol delivery system according to Clause 53, wherein the separation distance between the cartridge interface surface and the control unit interface surface is in the range of 0.3 mm to 2 mm.

[0297] Clause 55. An aerosol delivery system according to Clause 54, wherein the separation distance between the cartridge interface surface and the control unit interface surface is in the range of 0.5 mm to 1.5 mm.

[0298] Clause 56. A method for generating an aerosol from an aerosol generating substrate in an aerosol delivery system, wherein the aerosol delivery system comprises a cartridge and a control unit, the cartridge comprises a heating element providing at least a portion of a cartridge interface surface; the control unit comprises a control unit interface surface, and the method comprises

[0299] Step of connecting the cartridge to the control unit through an interface — the cartridge interface surface is adjacent to the control unit interface surface when the cartridge and the control unit are connected through the interface —,

[0300] A method comprising the step of heating a heating element by passing an electric current through the heating element to vaporize a portion of an aerosol generating substrate near the heating element.

[0301] Clause 57. As a method of Clause 56, heating a heating element by passing an electric current through it, thereby vaporizing a portion of the aerosol generating substrate near the heating element,

[0302] It includes the step of driving an induction element to induce current flow in a heating element to induce heating of the heating element;

[0303] A heating element comprises a susceptor, and a control unit comprises an induction assembly that provides a portion of the control unit interface surface, wherein the induction assembly comprises an induction element operable to induce a current flow from the heating element of the cartridge to induce heating of the heating element, thereby aerosolizing a portion of the aerosol generating substrate near the heating element, and wherein the induction element is provided near the control unit interface surface.

[0304] Clause 58. In the method of Clause 56, heating the heating element by passing an electric current through it and thereby vaporizing a portion of the aerosol generating substrate near the heating element,

[0305] It includes the step of supplying current through the resistive track between each part of the resistive track;

[0306] A heating element comprises a resistive track provided on a portion of the cartridge interface surface, and a control unit comprises a pair of electrical contacts configured to provide electrical connections with each portion of the resistive track when the cartridge and the control unit are connected through an interface.

[0307] Clause 59. A method according to any one of provisions 56 to 58, wherein the method comprises heating the heating element to a first temperature by passing an electric current through the heating element to vaporize a portion of the aerosol generating substrate near the heating element, and further comprising heating the heating element to a second temperature lower than the first temperature and lower than the temperature required to vaporize a portion of the aerosol generating substrate near the heating element by passing an electric current through the heating element.

[0308] Clause 60. In the method of Clause 59, the second temperature is a temperature in the range of 80°C to 200°C.

[0309] Clause 61. A method according to Article 59 or Article 60, wherein the method comprises heating the heating element to a second temperature by passing an electric current through the heating element in response to a stimulus, the stimulus comprising one or more of a signal indicating a connection to the control unit of the cartridge and a signal indicating a user's intention to start a usage session.

[0310] Clause 62. A method in any one of provisions 59 to 61, wherein the method comprises heating the heating element from a second temperature to a first temperature by flowing an electric current through the heating element in response to a signal indicating that the user is interacting with a user input element.

[0311] Clause 63. A method of Clause 62 comprising maintaining a heating element at a second temperature after a signal indicating that a user is interacting with a user input element is interrupted, and / or between signals indicating that a user is interacting with a user input element.

[0312] Clause 64. A method in any one of provisions 59 through 63, wherein the method comprises stopping the flow of current to the heating element to stop maintaining the heating element at a second temperature, and stopping the flow of current to the heating element to maintain the heating element at a second temperature after an inactive period.

[0313] Clause 65. In the method of Clause 64, the inactive period is in the range of 10 seconds to 120 seconds.

[0314] Clause 66. In any one of the methods of Articles 59 through 65, the method comprises engaging a connecting mechanism configured to hold a cartridge as part of an aerosol delivery system, and disengaging the connecting mechanism, wherein the connecting mechanism is electronically operable.

Claims

Claim 1 A cartridge for use in an aerosol delivery system for generating an aerosol from an aerosol-generating substrate, wherein the cartridge is configured to be connected to and disconnected from a control unit of the aerosol delivery system through an interface, the cartridge comprises a heating element, wherein the heating element is configured to aerosolize a portion of the aerosol-generating substrate in the vicinity of the heating element, and wherein the heating element provides at least a portion of the cartridge interface surface; wherein the cartridge interface surface is configured to be adjacent to the control unit interface surface when the cartridge and the control unit are connected through the interface. Claim 2 In claim 1, the heating element comprises a flat surface that provides at least a portion of the cartridge interface surface, the cartridge. Claim 3 In claim 1, the cartridge comprises a spacer protruding outwardly from the cartridge interface surface; optionally, the spacer protrudes outwardly from the cartridge interface surface by a distance ranging from 0.3 mm to 2 mm. Claim 4 In claim 1, the cartridge comprises a plurality of apertures extending through the heating element. Claim 5 In claim 4, the plurality of openings are arranged in a pattern, and the density of the plurality of openings varies from the peripheral edge of a portion of the cartridge interface surface toward the center of a portion of the cartridge interface surface; optionally, the density of the plurality of openings increases from the peripheral edge of a portion of the cartridge interface surface toward the center of a portion of the cartridge interface surface, cartridge. Claim 6 In claim 1, the heating element comprises a resistive track provided on the cartridge interface surface. Claim 7 In claim 1, the heating element comprises a susceptor; optionally, the susceptor comprises a planar element having a thickness in a range of at least one of 20 μm to 70 μm, 30 μm to 60 μm, and 40 μm to 55 μm, a cartridge. Claim 8 In claim 1, the cartridge comprises a removable cover adjacent to a portion of the cartridge interface surface. Claim 9 A mouthpiece for use in an aerosol delivery system, wherein the mouthpiece is configured to hold a cartridge according to any one of claims 1 to 8 within a cavity, and the mouthpiece comprises: an outlet for the aerosol delivery system; and an opening mechanism configured to allow the mouthpiece to move between a first configuration and a second configuration — wherein, in the first configuration, the cavity is at least partially exposed to allow the cartridge to be inserted and / or removed, and wherein, in the second configuration, the mouthpiece is configured to hold a cartridge provided within the cavity —; and optionally comprises at least one component of a connecting mechanism, wherein the connecting mechanism is configured to hold the mouthpiece in the second configuration. Claim 10 An induction assembly for use with a cartridge according to any one of claims 1 to 8, wherein the induction assembly comprises an induction element operable to induce a current flow in a heating element of the cartridge to induce heating of the heating element, thereby aerosolizing a portion of an aerosol generating substrate near the heating element, wherein the induction assembly provides at least a portion of a control unit interface surface, and the induction element is provided near the control unit interface surface. Claim 11 In claim 10, the induction element comprises an induction assembly comprising a pair of adjacent counter-rotating coils within a single plane. Claim 12 A control unit for use in an aerosol delivery system for generating an aerosol from an aerosol generating substrate, wherein the control unit comprises: an induction assembly of claim 10; a power supply device for supplying power to the induction element; and a control circuitry for controlling the power supply to the induction element, wherein the control circuitry is configured to drive the induction element to induce a current flow in the heating element to induce heating of the heating element, thereby vaporizing a portion of the aerosol generating substrate near the heating element. Claim 13 An aerosol delivery system for generating an aerosol from an aerosol generating substrate, wherein the aerosol delivery system comprises: a cartridge of any one of claims 1 to 8; a control unit of claim 12 — wherein an air path is provided between the cartridge interface surface and the control unit interface surface —; and optionally, a mouthpiece of claim 9. Claim 14 An aerosol delivery system according to claim 13, wherein the separation distance between the cartridge interface surface and the control unit interface surface is in the range of 0.3 mm to 2 mm; optionally, the separation distance between the cartridge interface surface and the control unit interface surface is in the range of 0.5 mm to 1.5 mm. Claim 15 A method for generating an aerosol from an aerosol generating substrate in an aerosol delivery system, wherein the aerosol delivery system comprises a cartridge and a control unit, the cartridge comprises a heating element providing at least a portion of a cartridge interface surface; the control unit comprises a control unit interface surface, and the method comprises the step of connecting the cartridge to the control unit through an interface ― the cartridge interface surface is adjacent to the control unit interface surface when the cartridge and the control unit are connected through the interface ―; and the step of heating the heating element by flowing an electric current through the heating element to vaporize a portion of the aerosol generating substrate near the heating element.

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