Aerosol-generating system with a cartridge having a side aperture

Abstract

An aerosol-generating system comprises a cartridge and an aerosol-generating device. The cartridge comprises a cartridge housing and a cartridge aerosol-forming substrate positioned within the cartridge housing. The cartridge housing has first and second ends and defines a cartridge axis extending between the first and second ends. At least one aperture is positioned on a first side of the cartridge between the first and second ends. The aerosol-generating device comprises a cavity to receive at least a portion of the cartridge, a cavity air inlet at an upstream end of the cavity, and a cavity air outlet at a downstream end of the cavity. The aerosol-generating system is configured to insert the cartridge into the cavity in a first direction parallel to the cartridge axis. The aerosol-generating device further comprises a liquid aerosol-forming substrate, an electric heater, a power supply, and a controller. When the cartridge is received within the cavity, the cartridge housing and the aerosol-generating device cooperate to direct an airflow from the cavity air inlet through the at least one aperture defined by the cartridge housing such that the airflow from the cavity air inlet to the cavity air outlet flows through the cartridge.

Description

[0001] This divisional application is based on patent application No. 201780072718.3 (International Application No. PCT / EP2017 / 080877), having the title "Aerosol-generating system with cartridge having side aperture", filed on 29 November 2017. TECHNICAL FIELD

[0002] The present invention relates to an aerosol-generating system comprising a cartridge having at least one aperture in one side of the cartridge. The invention is particularly useful as an electrically operated smoking system. BACKGROUND

[0003] One type of aerosol-generating system is an electrically operated smoking system. Known hand-held electrically operated smoking systems generally comprise an aerosol- generating device comprising a battery, control electronics and an electric heater for heating an aerosol-forming substrate. The aerosol-forming substrate can be contained within a portion of the aerosol-generating device. For example, the aerosol-generating device can comprise a liquid storage portion in which a liquid aerosol-forming substrate, such as a solution of nicotine, is stored. Such devices, often referred to as "e-cigarettes", typically contain sufficient liquid aerosol-forming substrate to provide a number of puffs equivalent to the consumption of a number of conventional cigarettes.

[0004] In order to provide e-cigarette users with an experience that more closely simulates the experience of consuming a conventional cigarette, some devices have attempted to combine the configuration of an e-cigarette with a tobacco-based substrate to impart a tobacco flavour to the aerosol inhaled by the user. However, the increased complexity of such devices compared to conventional e-cigarettes can result in a more complex manufacturing process and a diminished user experience.

[0005] It would be desirable to provide an aerosol-generating system comprising a plurality of aerosol-forming substrates and which mitigates or eliminates at least some of the problems of known devices. SUMMARY

[0006] According to the present application, there is provided an aerosol-generating system comprising a cartridge and an aerosol-generating device. The cartridge comprises a cartridge housing and a cartridge aerosol-forming substrate positioned within the cartridge housing. The cartridge housing has a first end and a second end and defines a cartridge axis extending between the first end and the second end. The cartridge housing further defines at least one aperture positioned on a first side of the cartridge between the first end and the second end of the cartridge housing. The aerosol-generating device comprises a cavity for receiving at least a portion of the cartridge, a cavity air inlet at an upstream end of the cavity and a cavity air outlet at a downstream end of the cavity, wherein the aerosol-generating system is configured for insertion of the cartridge into the cavity in a first direction parallel to the cartridge axis. The aerosol-generating device further comprises a liquid storage section comprising a liquid aerosol-forming substrate positioned within the liquid storage section, an electrical heater configured to heat the liquid aerosol-forming substrate from the liquid storage section during use of the aerosol-generating system, and a power supply section. The power supply section comprises a power supply and a controller for controlling the supply of electrical power from the power supply to the electrical heater. The aerosol-generating system is configured such that when the cartridge is received within the cavity, the cartridge housing and the aerosol-generating device cooperate to direct a flow of air from the cavity air inlet through the at least one aperture defined by the cartridge housing, such that the flow of air from the cavity air inlet to the cavity air outlet flows through the cartridge.

[0007] As used herein, the term "aerosol-forming substrate" is used to describe a substrate capable of releasing volatile compounds, which can form an aerosol. Aerosols produced by the aerosol- generating substrate of the aerosol-generating system according to the present application can be visible or invisible, and can comprise vapour (e.g. fine particles of a substance in a gaseous state, which is typically a liquid or solid at room temperature) as well as gas and droplets of condensed vapour.

[0008] The aerosol-generating system according to the present application is configured to direct a flow of air through the cartridge via at least one aperture on a side of the cartridge. Advantageously, providing at least one aperture on a side of the cartridge can facilitate improved air flow through the aerosol-generating system. For example, one or more condensation chambers can be provided coaxially with the cartridge, which can shorten the length of the aerosol-generating system compared to known systems in which the cartridge is configured for air flow through an aperture on an end of the cartridge.

[0009] Advantageously, providing at least one aperture on a side of the cartridge can facilitate an increase in the size of the at least one aperture compared to known systems in which an air flow aperture is provided at an end of the cartridge. Advantageously, a larger aperture can facilitate filling of the cartridge with cartridge aerosol-forming substrate. Advantageously, a larger aperture can increase the cross-sectional area of the cartridge for air flow into the cartridge, which can reduce the draw resistance of the aerosol-generating system. The increased flow area can also facilitate a reduction in the thickness of the cartridge aerosol-generating substrate compared to known systems, which can further reduce the draw resistance.

[0010] Preferably, the aerosol-generating system comprises at least one system air flow inlet and at least one system air flow outlet. During use, air flows through the aerosol-generating system along a flow path from the system air flow inlet to the system air flow outlet. The air flows along the flow path from an upstream end of the flow path at the system air flow inlet to a downstream end of the flow path at the system air flow outlet.

[0011] Preferably, the cartridge comprises a second side opposite the first side, wherein the cartridge aerosol-forming substrate is positioned between the first side and the second side. The at least one aperture can comprise a first aperture extending across at least a portion of the first side of the cartridge.

[0012] The first side can have a length extending parallel to the cartridge axis, wherein the first aperture extends along less than about 50% of the length of the first side. The first aperture can be positioned proximate to a first end of the cartridge housing, the at least one aperture further comprising a second aperture extending across a portion of the first side of the cartridge and spaced apart from the first aperture, the second aperture being positioned proximate to a second end of the cartridge housing. Advantageously, providing a first aperture positioned proximate to a first end of the cartridge and a second aperture positioned proximate to a second end of the cartridge can facilitate air flow through substantially the entire cartridge.

[0013] Preferably, the aerosol-generating device comprises an air flow blocking element extending from a side wall of the cavity towards the first side of the cartridge and positioned between the first aperture and the second aperture when the cartridge is received within the cavity. The air flow blocking element is configured such that, in use, when the cartridge is received within the cavity the air flow blocking element directs air flow from the cavity air inlet through the first aperture, across at least a portion of the cartridge aerosol-forming substrate, and through the second aperture to the cavity air outlet. Preferably, the cartridge housing defines a cartridge wall portion extending between the first aperture and the second aperture, wherein the air flow blocking element is configured to engage the cartridge wall portion when the cartridge is received within the cavity.

[0014] The first aperture can be positioned proximate a first end of the cartridge housing, and the at least one aperture can further comprise a second aperture extending across a portion of a second side of the cartridge, the second aperture being positioned proximate a second end of the cartridge housing. Advantageously, this arrangement can facilitate air flow through substantially the entire cartridge.

[0015] Preferably, the aerosol-generating device comprises a first air flow blocking element extending from a first side wall of the cavity towards a first side of the cartridge and positioned downstream of the first aperture when the cartridge is received within the cavity. Preferably, the aerosol-generating device comprises a second air flow blocking element extending from a second side wall of the cavity towards a second side of the cartridge and positioned upstream of the second aperture when the cartridge is received within the cavity. The first and second air flow blocking elements are configured such that, in use, the first air flow blocking element directs air flow from the cavity air inlet through the first aperture, across at least a portion of the cartridge aerosol-forming substrate, and through the second aperture, wherein the second air flow blocking element directs air flow to the cavity air outlet. Preferably, the cartridge housing defines a first cartridge wall portion proximate the first aperture and a second cartridge wall portion proximate the second aperture, wherein the first air flow blocking element is configured to engage the first cartridge wall portion and the second air flow blocking element is configured to engage the second cartridge wall portion when the cartridge is received within the cavity.

[0016] The first side of the cartridge can have a length extending parallel to the cartridge axis, wherein the first aperture extends along at least about 50% of the length of the first side. Advantageously, this arrangement can provide a first aperture that is sufficiently large to provide a desirable draw resistance for the aerosol-generating system. Advantageously, this arrangement can provide a first aperture that is sufficiently large to facilitate filling of the cartridge housing with cartridge aerosol-forming substrate during manufacture of the cartridge. The first aperture can extend along substantially the entire length of the first side.

[0017] The first aperture can be the only aperture defined by the cartridge housing. Preferably, the aerosol-generating device comprises an air flow blocking element extending from a side wall of the cavity towards a first side of the cartridge, the air flow blocking element being positioned to direct air flow from the cavity air inlet through the first aperture, across at least a portion of the cartridge aerosol-forming substrate, and back through the first aperture to the cavity air outlet.

[0018] In embodiments where the first aperture extends along at least about 50% of the length of the first side of the cartridge, the at least one aperture can further comprise a second aperture extending across at least a portion of the second side of the cartridge. Preferably, the second side has a length extending parallel to the cartridge axis, wherein the second aperture extends along at least about 50% of the length of the second side, and wherein the second aperture at least partially overlaps the first aperture. Advantageously, this arrangement can reduce the draw resistance of the aerosol-generating system by facilitating the directing of an air flow from the first aperture to the second aperture across the cartridge aerosol-forming substrate. The first aperture can extend along substantially the entire length of the first side. The second aperture can extend along substantially the entire length of the second side.

[0019] The cartridge housing can define a plurality of substrate compartments, wherein the cartridge aerosol-forming substrate is positioned within at least one of the substrate compartments. The cartridge can comprise a plurality of cartridge aerosol-forming substrates, wherein each cartridge aerosol-forming substrate is positioned within one of the substrate compartments. The plurality of cartridge aerosol-forming substrates can be different from one another, or they can be the same.

[0020] At least one of the substrate compartments can not contain a cartridge aerosol-forming substrate. At least one of the substrate compartments can contain a filter material. The filter material can comprise cellulose acetate. At least one of the substrate compartments can contain a flavourant. The flavourant can comprise menthol.

[0021] Preferably, the first aperture overlies a first side of each of the substrate compartments, the at least one aperture further comprising a second aperture extending across at least a portion of a second side of the cartridge, the second aperture overlying a second side of each of the substrate compartments.

[0022] The aerosol-generating system can be configured to facilitate a parallel flow of air through each of the substrate compartments. The cavity air inlet can be positioned to provide an air flow to the first aperture, and the cavity air outlet can be positioned to receive an air flow from the aperture.

[0023] Preferably, the aerosol-generating system is configured to facilitate a serial flow of air through each of the substrate compartments. The aerosol-generating device can comprise at least one air flow blocking element. The at least one air flow blocking element is positioned within the cavity to direct an air flow through each of the substrate compartments when the cartridge is received within the cavity. The at least one air flow blocking element can form part of the device housing. Preferably, the at least one air flow blocking element is configured to direct an air flow along a serpentine air flow path through the substrate compartments via the first and second apertures during use of the aerosol-generating system.

[0024] The at least one air flow blocking element can comprise a set of one or more first air flow blocking elements extending from a first wall of the cavity and a set of one or more second air flow blocking elements extending from a second wall of the cavity opposite the first wall, wherein the first air flow blocking elements are spaced apart along the first wall in a downstream direction and the second air flow blocking elements are spaced apart along the second wall in the downstream direction, and wherein the first air flow blocking elements are offset from the second air flow blocking elements when the cartridge assembly is received within the cavity to define a serpentine air flow path through the cavity and the substrate compartment.

[0025] Advantageously, defining a serpentine flow path ensures that the air flow through the aerosol-generating system flows through each substrate compartment.

[0026] As described herein, the cartridge can comprise a second side opposite the first side. In embodiments in which the at least one aperture comprises only a first aperture positioned on the first side of the cartridge or a first and second aperture positioned on the first side of the cartridge, the cartridge housing can comprise a wall portion defining the second side of the cartridge, wherein the wall portion is curved. Advantageously, providing a curved wall portion defining the second side of the cartridge can maximise the internal volume of the cartridge, which can increase the amount of cartridge aerosol-forming substrate that can be positioned within the cartridge. Advantageously, providing a curved wall portion can provide rotational asymmetry to the cartridge, which can facilitate a user inserting the cartridge into the cavity in the correct orientation.

[0027] The first end of the cartridge housing can extend at a non-perpendicular angle relative to the cartridge axis, wherein the cartridge and aerosol-generating device are configured such that a portion of the first end of the cartridge housing abuts the upstream end wall of the cavity when the cartridge is received within the cavity, such that the first end of the cartridge housing directs air flow from the cavity air inlet to the first side of the cartridge. Advantageously, in particular in embodiments in which the cartridge comprises a single substrate compartment, a first aperture on the first side of the cartridge, and a second aperture on the second side of the cartridge, this arrangement can not require the provision of one or more air flow blocking elements in the cavity.

[0028] The aerosol-generating system can comprise a mouthpiece. The mouthpiece can form part of the cartridge. The mouthpiece can be formed separately from the cartridge and configured for attachment to at least one of the cartridge and the vaporiser section, for example by an interference fit. Preferably, the mouthpiece comprises a mouthpiece air outlet configured for fluid communication with the cavity air outlet during use. In embodiments in which the aerosol-generating system comprises at least one system air flow outlet, the mouthpiece air outlet can form the system air flow outlet.

[0029] Preferably, the cartridge is configured to be retained within the cavity by an interference fit. Each of the cartridge and the cavity can have any suitable cross-sectional shape. Preferably, the cross-sectional shape of the cartridge is substantially the same as the cross-sectional shape of the cavity. Suitable cross-sectional shapes include circular, semi-circular, polygonal, for example rectangular, including square, and irregular shapes.

[0030] The cartridge housing can be formed from any suitable material or combination of materials. Suitable materials include, but are not limited to, aluminium, polyether ether ketone (PEEK), polyimide (for example Kapton® ), polyethylene terephthalate (PET), polyethylene (PE), high-density polyethylene (HDPE), polypropylene (PP), polystyrene (PS), fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyoxymethylene (POM), epoxy resin, polyurethane resin, vinyl resin, liquid crystal polymer (LCP) and modified LCP, for example LCP with graphite or glass fibres.

[0031] The cartridge can comprise a layer of porous material extending across the at least one aperture. In embodiments in which the at least one aperture comprises a first aperture, the layer of porous material can comprise a first layer of porous material extending across the first aperture. In embodiments in which the at least one aperture comprises a second aperture, the layer of porous material can comprise a second layer of porous material extending across the first aperture. Advantageously, the one or more layers of porous material can retain the cartridge aerosol-forming substrate within the cartridge and also allow airflow through the cartridge. Each layer of porous material can comprise a mesh.

[0032] The cartridge aerosol-forming substrate can comprise a solid aerosol-forming substrate. The solid aerosol-forming substrate can comprise tobacco. The solid aerosol-forming substrate can comprise a tobacco-containing material, the tobacco-containing material containing volatile tobacco flavour compounds that are released from the substrate upon heating.

[0033] The solid aerosol-forming substrate can comprise tobacco containing deprotonated nicotine. Deprotonating nicotine within the tobacco can advantageously increase the volatility of the nicotine. The nicotine can be deprotonated by subjecting the tobacco to an alkalisation treatment.

[0034] The solid aerosol-forming substrate can comprise a non-tobacco material. The solid aerosol-forming substrate can comprise a tobacco-containing material and a non-tobacco-containing material.

[0035] The solid aerosol-forming substrate can comprise at least one aerosol-former. As used herein, the term 'aerosol-former' is used to describe any suitable known compound or mixture of compounds which, in use, assists in the formation of an aerosol. Suitable aerosol-formers include, but are not limited to: polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerol; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or poly-carboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0036] A preferred aerosol-former is a polyhydric alcohol or mixture thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol and most preferably glycerol.

[0037] The solid aerosol-forming substrate can comprise a single aerosol-former. Alternatively, the solid aerosol-forming substrate can comprise a combination of two or more aerosol-formers.

[0038] The solid aerosol-forming substrate can have an aerosol-former content of greater than 5% by dry weight.

[0039] The solid aerosol-forming substrate can have an aerosol-former content of between about 5% and about 30% by dry weight.

[0040] The solid aerosol-forming substrate can have an aerosol-former content of about 20% by dry weight.

[0041] The liquid aerosol-forming substrate of the liquid storage segment can comprise a tobacco- containing material which includes volatile tobacco flavour compounds which are released from the liquid upon heating. The liquid aerosol-forming substrate can comprise a non-tobacco material. The liquid aerosol-forming substrate can comprise water, a solvent, ethanol, a plant extract and a natural or artificial flavourant. Preferably, the liquid aerosol-forming substrate comprises an aerosol-former. Suitable aerosol-formers include polyhydric alcohols or mixtures thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerol.

[0042] The liquid aerosol-forming substrate in the liquid storage segment can comprise nicotine.

[0043] The liquid aerosol-forming substrate can be free of nicotine. In such embodiments, the vaporised liquid aerosol-forming substrate can be drawn through the solid aerosol-forming substrate of one of the cartridges during use to strip one or more volatile compounds from the solid aerosol-forming substrate. The vaporised liquid aerosol-forming substrate can strip nicotine from the solid aerosol-forming substrate. Cartridges having a solid aerosol-forming substrate comprising tobacco containing deprotonated nicotine can be particularly suitable for embodiments in which the liquid aerosol-forming substrate is free of nicotine.

[0044] The liquid storage section can comprise a porous carrier material, wherein the liquid aerosol-forming substrate is disposed on the porous carrier material. Advantageously, disposing the liquid aerosol-forming substrate on a porous carrier material can reduce the risk of leakage of the liquid aerosol-forming substrate from the liquid storage section.

[0045] The porous carrier material can comprise any suitable material or combination of materials that is permeable to the liquid aerosol-forming substrate and allows the liquid aerosol-forming substrate to migrate through the porous carrier material. Preferably, the material or combination of materials is inert with respect to the liquid aerosol-forming substrate. The porous carrier material can or can not be a capillary material. The porous carrier material can comprise a hydrophilic material to improve the distribution and spreading of the liquid aerosol-forming substrate. This can help to form a consistent aerosol. Particularly preferred materials will depend on the physical properties of the liquid aerosol-forming substrate. Examples of suitable materials are capillary materials, such as sponge or foam materials, ceramic or graphite-based materials in the form of fibres or sintered powders, foam metals or plastics materials, for example fibrous materials made from spun or extruded fibres, such as cellulose acetate, polyester or bonded polyolefins, polyethylene, terylene or polypropylene fibres, nylon fibres or ceramics. The porous carrier material can have any suitable porosity for use with different liquid physical properties.

[0046] The cartridge aerosol-forming substrate can comprise a liquid aerosol-forming substrate. The liquid aerosol-forming substrate can be disposed on a porous carrier material positioned within the cartridge. Suitable liquid aerosol-forming substrates include those described herein with respect to the liquid storage section of the aerosol-generating device. Suitable porous carrier materials include those described herein with respect to the liquid storage section of the aerosol-generating device. Preferably, the liquid aerosol-forming substrate disposed in the cartridge is different to the liquid aerosol-forming substrate disposed in the liquid storage section of the aerosol-generating device.

[0047] In embodiments in which the cartridge aerosol-forming substrate comprises a plurality of cartridge aerosol-forming substrates positioned within a plurality of substrate compartments, preferably at least two of the aerosol-forming substrates comprise different aerosol-forming substrates. One of the cartridge aerosol-forming substrates can comprise a solid aerosol-forming substrate as described herein. One of the cartridge aerosol-forming substrates can comprise a liquid aerosol-forming substrate as described herein.

[0048] The cartridge can comprise a seal extending over the at least one aperture. In embodiments in which the at least one aperture comprises a first aperture, the seal can comprise a first seal extending across the first aperture. In embodiments in which the at least one aperture comprises a second aperture, the seal can comprise a second seal extending across the first aperture. Preferably, each seal is a removable seal. A user removes each seal from the cartridge prior to inserting the cartridge into the cavity.

[0049] Preferably, each seal is fastened to the cartridge housing about a periphery of the seal. Each seal can be fastened to the cartridge housing by at least one of an adhesive and a weld (e.g., an ultrasonic weld).

[0050] Each seal is preferably formed of a sheet material. The sheet material can include at least one of a polymeric film and a metal foil.

[0051] The aerosol-generating system can further comprise a liquid transport element configured such that, in use, liquid aerosol-forming substrate is transported along the liquid transport element from the liquid storage section to the electric heater by capillary action. In embodiments in which the liquid storage section comprises a porous carrier material, the liquid transport element is configured to transport liquid aerosol-forming substrate from the porous carrier material to the electric heater.

[0052] The liquid transport element can comprise any suitable material or combination of materials capable of transporting liquid aerosol-forming substrate along its length. The liquid transport element can be formed of a porous material, but need not be. The liquid transport element can be formed of a material having a fibrous or sponge-like structure. The liquid transport element preferably comprises a bundle of capillaries. For example, the liquid transport element can comprise a plurality of fibres or filaments, or other fine bore tubes. The liquid transport element can comprise a sponge-like or foam-like material. Preferably, the structure of the liquid transport element forms a plurality of small pores or tubes through which liquid aerosol-forming substrate can be carried by capillary action. The particularly preferred material will depend on the physical properties of the liquid aerosol-forming substrate. Examples of suitable capillary materials include sponge or foam materials, ceramic or graphite-based materials in the form of fibres or sintered powders, foam metals or plastics materials, for example fibrous materials made from spun or extruded fibres, for example cellulose acetate, polyester or bonded polyolefin, polyethylene, terylene or polypropylene fibres, nylon fibres, ceramic, glass fibres, silica glass fibres, carbon fibres, metal fibres such as austenitic 316 stainless steel and martensitic 440 and 420 stainless steel alloys of medical grade. The liquid transport element can have any suitable capillarity for use with different liquid physical properties. The liquid aerosol-forming substrate has physical properties, including but not limited to viscosity, surface tension, density, thermal conductivity, boiling point and vapour pressure, which allow the liquid aerosol-forming substrate to be carried via the liquid transport element. The liquid transport element can be formed of a heat resistant material. The liquid transport element can comprise a plurality of fibre strands. The plurality of fibre strands can be substantially aligned along the length of the liquid transport element.

[0053] In embodiments in which the liquid storage section comprises a porous carrier material, the porous carrier material and the liquid transport element can comprise the same material. Preferably, the porous carrier material and the liquid transport element comprise different materials.

[0054] The electric heater can be provided separately from one or both of the liquid storage section and the power supply section. Preferably, the liquid storage section, the electric heater, and, where present, the liquid transfer element are provided together in a vaporiser section. Preferably, the vaporiser section comprises a vaporiser housing forming part of the device housing, wherein the vaporiser housing comprises an upstream end configured for connection to the power supply section and a downstream end defining a cavity configured to receive the cartridge assembly. Advantageously, providing the liquid storage section, the electric heater, and, where present, the liquid transfer element in a single vaporiser section separate from the power supply section can facilitate replacement of the vaporiser section (e.g. when the liquid aerosol-forming substrate has been depleted) without the need to replace the power supply section.

[0055] The electric heater can comprise an electrically resistive heating coil.

[0056] The electric heater can comprise an electrically resistive heating mesh.

[0057] The electrically resistive heating mesh can comprise a plurality of electrically conductive filaments. The electrically conductive filaments can be substantially planar. As used herein, "substantially planar" means formed in a single plane and not wound or otherwise conformed to a curved or other non-planar shape. A planar heating mesh can be easy to handle during manufacture and provide a robust construction.

[0058] The electrically conductive filaments can define interstices between the filaments, and the interstices can have a width of between about 10 microns and about 100 microns. Preferably, the filaments induce capillary action in the interstices, such that, in use, liquid aerosol-forming substrate is drawn into the interstices, thereby increasing the contact area between the heater assembly and the liquid.

[0059] The electrically conductive filaments can form a mesh of between about 160 Mesh US and about 600 Mesh US (+ / - 10%), i.e. between about 160 and about 600 filaments per inch (+ / - 10%). The width of the interstices is preferably between about 75 microns and about 25 microns. The percentage of open area of the mesh, i.e. the ratio of the area of the interstices to the total area of the mesh, is preferably between about 25% and about 56%. The mesh can be formed using different types of weave or lattice structure. The electrically conductive filaments can be an array of filaments arranged parallel to each other.

[0060] The electrically conductive filaments can have a diameter of between about 8 microns and about 100 microns, preferably between about 8 microns and about 50 microns, and more preferably between about 8 microns and about 39 microns.

[0061] The resistive heating mesh can cover an area less than or equal to about 25 square millimeters. The resistive heating mesh can be rectangular. The resistive heating mesh can be square. The resistive heating mesh can have dimensions of about 5 millimeters by about 2 millimeters.

[0062] The electrically conductive filaments can comprise any suitable electrically conductive material. Suitable materials include, but are not limited to, for example, doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites made from ceramic and metallic materials. Such composites can include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, Constantan, nickel-containing alloys, cobalt-containing alloys, chromium-containing alloys, aluminum-containing alloys, titanium-containing alloys, zirconium-containing alloys, hafnium-containing alloys, niobium-containing alloys, molybdenum-containing alloys, tantalum-containing alloys, tungsten-containing alloys, tin-containing alloys, gallium-containing alloys, manganese-containing alloys, and iron-containing alloys, as well as nickel-, iron-, and cobalt-based superalloys, stainless steels, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. is a registered trademark of Titanium Metals Corporation. The filaments can be coated with one or more insulators. Preferred materials for the electrically conductive filaments are 304, 316, 304L, and 316L stainless steel and graphite.

[0063] The resistive heating mesh preferably has a resistance of between about 0.3 and about 4 ohms. More preferably, the mesh has a resistance of between about 0.5 and about 3 ohms, and more preferably about 1 ohm.

[0064] In embodiments in which the electrical heater comprises a resistive heating coil, the pitch of the coil is preferably between about 0.5 millimeters and about 1.5 millimeters, and most preferably about 1.5 millimeters. The pitch of the coil means the spacing between adjacent turns of the coil. The coil can comprise less than six turns, and preferably has less than five turns. The coil can be formed from a resistive wire having a diameter of between about 0.10 millimeters and about 0.15 millimeters, and preferably about 0.125 millimeters. The resistive wire is preferably formed from 904 or 301 stainless steel. Examples of other suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of other suitable metal alloys include Constantan, nickel-containing alloys, cobalt-containing alloys, chromium-containing alloys, aluminum-containing alloys, titanium-containing alloys, zirconium-containing alloys, hafnium-containing alloys, niobium-containing alloys, molybdenum-containing alloys, tantalum-containing alloys, tungsten-containing alloys, tin-containing alloys, gallium-containing alloys, manganese-containing alloys, and iron-containing alloys, as well as nickel-, iron-, and cobalt-based superalloys, stainless steels, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. The resistive heating coil can also comprise a metal foil, such as aluminum foil, provided in the form of a ribbon.

[0065] The power source may include a battery. For example, the power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery, such as a lithium cobalt, lithium iron phosphate, or lithium polymer battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows sufficient energy to be stored for use by the aerosol generating device and more than one cylinder assembly. Attached Figure Description

[0066] The invention will be further described by way of example only with reference to the accompanying drawings, in which:

[0067] Figure 1 This is a perspective view of an aerosol generation system according to a first embodiment of the present invention;

[0068] Figure 2 yes Figure 1 Exploded perspective view of the cylinder of the aerosol generation system;

[0069] Figure 3 yes Figure 1 Cross-sectional view of the aerosol generation system;

[0070] Figure 4 This is an exploded perspective view of the cylinder according to a second embodiment of the present invention;

[0071] Figure 5 This is an exploded perspective view of a cylinder according to a third embodiment of the present invention;

[0072] Figure 6 It includes Figure 5 A cross-sectional view of the aerosol generation system of the cylinder;

[0073] Figure 7 This is an exploded perspective view of a cylinder according to a fourth embodiment of the present invention;

[0074] Figure 8 It includes Figure 7 A cross-sectional view of the aerosol generation system of the cylinder;

[0075] Figure 9 This is a perspective view of a cylinder according to a fifth embodiment of the present invention;

[0076] Figure 10 yes Figure 9 Exploded perspective view of the cylinder;

[0077] Figure 11 It includes Figure 9 and 10 A cross-sectional view of the aerosol generation system of the cylinder;

[0078] Figure 12This is an exploded perspective view of a cylinder according to a sixth embodiment of the present invention;

[0079] Figure 13 It includes Figure 12 A cross-sectional view of the aerosol generation system of the cylinder;

[0080] Figure 14 This is an exploded perspective view of a cylinder according to a seventh embodiment of the present invention;

[0081] Figure 15 It includes Figure 14 A cross-sectional view of the aerosol generation system of the cylinder;

[0082] Figure 16 This is a perspective view of a cylinder according to the eighth embodiment of the present invention; and

[0083] Figure 17 yes Figure 16 An exploded perspective view of the cylinder. Detailed Implementation

[0084] Figure 1 A perspective view of an aerosol generation system 10 according to a first embodiment of the present invention is shown. The aerosol generation system 10 includes an aerosol generation device 12, which includes a power supply section 14 and an evaporator section 16. The aerosol generation system 10 also includes a cylinder 18 and a nozzle 20 forming a portion of the cylinder 18. The evaporator section 16 includes an evaporator housing 22 forming a portion of a device housing 24. The downstream end of the evaporator housing 22 defines a cavity 26 for receiving the cylinder 18.

[0085] Figure 2 An exploded perspective view of the cylinder 18 is shown. The cylinder 18 includes a shell 28 having a first end 30 and a second end 32, the shell 28 defining a cylinder axis 34 extending between the first end 30 and the second end 32. The shell 28 defines a first orifice 36 on a first side of the cylinder 18 and a second orifice 38 on a second side of the cylinder 18 opposite to the first side. A first layer and a second layer of porous material 40 in the form of a mesh sieve extend across the first orifice 36 and the second orifice 38 to retain the cylinder aerosol forming matrix 42 within the shell 28.

[0086] Figure 3 A cross-sectional view is shown of the aerosol generation system 10 in which the cylinder 18 is received within the cavity 26. The cylinder 18 is positioned along a first direction 35 parallel to the cylinder axis 34. Figure 1 Insert it into cavity 26.

[0087] The power supply section 14 includes a system air inlet 46 for allowing air to enter the power supply section 14, a controller 48, and a power supply 50.

[0088] Evaporator section 16 includes an evaporator air inlet 52 for receiving air from power section 14, an air flow channel 54 in fluid communication with the evaporator air inlet 52 at an upstream end, and a cavity air inlet 56 in fluid communication between the downstream end of the air flow channel 54 and the cavity 26.

[0089] Evaporator section 16 further includes a liquid storage section 57 comprising a liquid aerosol forming matrix 58, which is adsorbed into an annular porous support material 60 positioned outside the airflow channel 54. A liquid delivery element 62, including a capillary wick, has a first end and a second end positioned in contact with the porous support material 60, and a central portion positioned within the airflow channel 54. The liquid aerosol forming matrix 58 is capillarily drawn from the porous support material 60 to the central portion of the capillary wick along the capillary wick.

[0090] Evaporator section 16 also includes an electric heater 64 comprising a resistance heating coil wound around the central portion of the capillary wick. During operation of the aerosol generation system 10, controller 48 controls the electrical energy supply from power source 50 to electric heater 64 to heat and evaporate the liquid aerosol forming matrix 58 from the central portion of the capillary wick.

[0091] The downstream portion of the evaporator housing 22 defines a plurality of airflow blocking elements 66 extending into the cavity 26. The airflow blocking elements 66 are configured such that when the cylinder 18 is received within the cavity 26, the airflow blocking elements 66 cooperate with the cylinder 18 to define an airflow path through the cavity 26 and the cylinder 18 via a first orifice 36 and a second orifice 38 of the cylinder 18.

[0092] At the downstream end of cavity 26 is cavity air outlet 70, which provides fluid communication between cavity 26 and nozzle 20. Nozzle 20 defines nozzle air outlet 72 for providing airflow from aerosol generation system 10 to user.

[0093] During use of the aerosol generation system 10, air is drawn into the system through the system air inlet 46, through the evaporator air inlet 52, and into the airflow channel 54, where the evaporated liquid aerosol forming matrix 58 is entrained in the airflow. The airflow then flows through the cavity air inlet 56, into the cavity 26 and the cylinder 18, where volatile compounds from the cylinder aerosol forming matrix 42 are entrained in the airflow. The airflow then flows out of the cylinder 18 and back into the cavity 26, exiting the aerosol generation system 10 through the cavity air outlet 70 and through the nozzle air outlet 72 to deliver the evaporated liquid aerosol forming matrix 58 and volatile compounds from the cylinder aerosol forming matrix 42 to the user.

[0094] Figure 4 An exploded perspective view of a cylinder 118 according to a second embodiment of the present invention is shown. The cylinder 118 is similar to... Figures 1 to 3 The cylinder 18 shown is used, and similar reference numerals are used to indicate similar parts.

[0095] Cylinder 118 differs from cylinder 18 by adding a partition wall portion 129 to cylinder housing 128. The partition wall portion 129 divides the cylinder into a first matrix compartment 131 and a second matrix compartment 133. Cylinder 118 includes a first cylinder aerosol forming matrix 42 positioned within the first matrix compartment 131 and a second cylinder aerosol forming matrix 143 positioned within the second matrix compartment 133. Otherwise, cylinder 118 is constructed identically to cylinder 18 (for clarity, from...). Figure 4 (20) Omitted the mouthpiece.

[0096] Figure 5 An exploded perspective view of a cylinder 218 according to a third embodiment of the present invention is shown. Cylinder 218 is similar to... Figure 4 Cylinder 118 is shown, and similar reference numerals are used to indicate similar parts. Cylinder 218 differs by adding a second partition wall portion 229 to the cylinder housing 228 to create a third matrix compartment 135, in which a third cylinder aerosol forming matrix 245 is positioned. Otherwise, cylinder 218 is constructed identically to cylinder 118 (for clarity, from...) Figure 5 (20) Omitted the mouthpiece.

[0097] Figure 6 Showing includes Figure 5 A cross-sectional view of the aerosol generation system 200 of cylinder 218. The aerosol generation system 200 is similar to... Figure 1 and 3 The aerosol generation system 10, and similar reference numerals are used to indicate similar parts.

[0098] Aerosol generation system 200 includes and Figure 1 and 3 The aerosol generating apparatus 12 is substantially the same as the aerosol generating apparatus 212, except for the configuration of the cavity 226. Specifically, the cavity 226 includes additional airflow blocking elements 267, wherein a plurality of blocking elements 66, 267 are configured such that when the cylinder 218 is received within the cavity 226, the airflow blocking elements 66, 267 cooperate with the cylinder 218 to define a meandering airflow path through the first orifice 36 and the second orifice 38 of the cylinder 218 through the cavity 26 and each of the substrate compartments 131, 133, 135.

[0099] Figure 7 An exploded perspective view of a cylinder 318 according to a fourth embodiment of the present invention is shown. Cylinder 318 is similar to... Figures 1 to 3The cylinder 18 is shown, and similar reference numerals are used to indicate similar parts. Cylinder 318 is distinguished by adding a wall portion 329 to the second side of the cylinder housing 328, such that cylinder 318 includes only the first orifice 36. That is, cylinder 318 does not include the second orifice.

[0100] Figure 8 Showing includes Figure 7 A cross-sectional view of the aerosol generation system 300 of cylinder 318. The aerosol generation system 300 is similar to... Figure 1 and 3 The aerosol generation system 10, and similar reference numerals are used to indicate similar parts.

[0101] Aerosol generation system 300 includes and Figure 1 and 3 The aerosol generating apparatus 12 is substantially the same as the aerosol generating apparatus 312, except for the configuration of the cavity 326. Specifically, the cavity 326 includes a different configuration of the airflow blocking element 366, which is arranged such that when the cylinder 318 is received within the cavity 326, the airflow blocking element 366 cooperates with the cylinder 318 to guide airflow into the cylinder 318 through the upstream end of the first orifice 36, and then out of the cylinder 318 through the downstream end of the first orifice 36.

[0102] Figure 9 and 10 A cylinder 418 according to a fifth embodiment of the present invention is shown. Cylinder 418 is similar to... Figure 7 The cylinder 318 is shown in the figure, and similar reference numerals are used to indicate similar parts. The cylinder 418 is distinguished by adding a wall portion 429 to the first side of the cylinder housing 428, such that the cylinder 418 includes a first orifice 436 on the first side of the cylinder 418 and adjacent to the first end 30 and a second orifice 438 on the first side of the cylinder 418 and adjacent to the second end 32.

[0103] Figure 11 Showing includes Figure 9 and 10 A cross-sectional view of the aerosol generation system 400 of cylinder 418. The aerosol generation system 400 is similar to... Figure 8 The aerosol generation system 300, and similar reference numerals are used to indicate similar parts.

[0104] Aerosol generation system 400 includes and Figure 8The aerosol generating apparatus 312 is substantially the same as the aerosol generating apparatus 412, except for the configuration of the cavity 426. Specifically, adding a wall portion 429 to the first side of the cylinder 418 allows for the use of fewer airflow blocking elements 466 in the cavity 426. The airflow blocking elements 466 are arranged such that when the cylinder 418 is received within the cavity 426, the airflow blocking elements 466 cooperate with the cylinder 418 to guide airflow into the cylinder 418 through a first orifice 436 and then out of the cylinder 418 through a second orifice 438.

[0105] Figure 12 A cylinder 518 according to a sixth embodiment of the present invention is shown. The cylinder 518 is similar to... Figure 9 and 10 The cylinder 418 is shown in the figure, and similar reference numerals are used to indicate similar parts. The cylinder 518 differs in the position of the second orifice 538. Specifically, the second orifice 538 is located on the second side of the cylinder 518 and adjacent to the second end 32.

[0106] Figure 13 Showing includes Figure 12 A cross-sectional view of the aerosol generation system 500 of cylinder 518. The aerosol generation system 500 is similar to... Figure 11 The aerosol generation system 400, and similar reference numerals are used to indicate similar parts.

[0107] Aerosol generation system 500 includes and Figure 11 The aerosol generating device 412 is basically the same as the aerosol generating device 512, except for the position of the cavity air outlet 570.

[0108] Figure 14 A cylinder 618 according to a seventh embodiment of the present invention is shown. The cylinder 618 is similar to... Figures 1 to 3 The cylinder 18 is shown, and similar reference numerals are used to indicate similar parts. The cylinder 618 differs in the configuration of its first end 630. Specifically, the cylinder housing 628 includes a wall portion 629 located at the first end 630 of the cylinder, wherein the wall portion 629 extends at a non-orthogonal angle relative to the cylinder axis 34.

[0109] Figure 15 Showing includes Figure 14 A cross-sectional view of the aerosol generation system 600 of cylinder 618. The aerosol generation system 600 is similar to... Figure 1 and 3 The aerosol generation system 10, and similar reference numerals are used to indicate similar parts.

[0110] Aerosol generation system 600 includes and Figure 1 and 3The aerosol generating device 12 is substantially the same as the aerosol generating device 612, except for the configuration of the cavity 626. Specifically, the angled first end 630 of the cylinder 618 eliminates the need for any airflow blocking elements in the cavity 626. In fact, the aerosol generating system 600 is configured such that when the cylinder 618 is received within the cavity 626, the angled first end 630 of the cylinder 618 abuts against the upstream end wall 627 of the cavity 626. In this configuration, the angled first end 630 of the cylinder 618 guides airflow from the cavity air inlet 56 to a first side of the cylinder 618, wherein air flows through the cylinder 618 via a first orifice 36 and a second orifice 38.

[0111] Figure 16 and 17 A cylinder 718 according to an eighth embodiment of the present invention is shown. The cylinder 718 is similar to... Figure 9 and 10 The cylinder 418 is shown in the figure, and similar reference numerals are used to indicate similar parts. The cylinder 718 differs in the configuration of the wall portion 729 forming the second side of the cylinder 718. Specifically, the wall portion 729 is bent to form the bent second side of the cylinder 718. The cylinder 718 can be combined with... Figure 11 The aerosol generating apparatus 412 is substantially the same as the aerosol generating apparatus but has a cavity with a modified shape that is shaped into a receiving cylinder 718.

Claims

1. An aerosol generation system, the aerosol generation system comprising: A cylinder, the cylinder including a cylinder shell and a cylinder aerosol forming matrix positioned within the cylinder shell, the cylinder shell having a first end and a second end and defining a cylinder axis extending between the first end and the second end, the cylinder shell further defining a first orifice positioned on a first side of the cylinder and between the first end and the second end of the cylinder shell; Aerosol generating apparatus, the aerosol generating apparatus comprising: A cavity for receiving at least a portion of the cylinder, a cavity air inlet at an upstream end of the cavity, and a cavity air outlet at a downstream end of the cavity, wherein the aerosol generation system is configured to insert the cylinder into the cavity along a first direction parallel to the cylinder axis; A liquid storage section, the liquid storage section including a liquid aerosol forming matrix positioned within the liquid storage section; An electric heater, configured to heat the liquid aerosol forming matrix from the liquid storage section during use of the aerosol generation system; and A power supply section, comprising a power source and a controller for controlling the power supply from the power source to the electric heater; and The aerosol generation system is configured such that, when the cylinder is received within the cavity, the cylinder housing and the aerosol generation device cooperate to guide an airflow from the cavity air inlet through a first orifice defined by the cylinder housing, such that an airflow from the cavity air inlet to the cavity air outlet flows through the cylinder; and The aerosol generating device includes an airflow blocking element extending from the sidewall of the cavity toward the first side of the cylinder, the airflow blocking element being positioned to guide airflow from the cavity air inlet through the first orifice, across at least a portion of the cylinder aerosol forming matrix, and back through the first orifice to the cavity air outlet.

2. The aerosol generation system of claim 1, wherein the cylinder includes a second side opposite to the first side, wherein the cylinder aerosol forming matrix is ​​positioned between the first side and the second side, and wherein the first orifice extends across at least a portion of the first side of the cylinder.

3. The aerosol generation system of claim 2, wherein the cylinder shell includes a wall portion defining a second side of the cylinder, and wherein the wall portion is curved.

4. The aerosol generation system according to any one of claims 1-3, wherein the first side has a length extending parallel to the cylinder axis, wherein the first orifice extends along at least 50% of the length of the first side.

5. The aerosol generation system according to any one of claims 1-3, wherein the first orifice is a single orifice defined by the cylindrical shell.

6. The aerosol generating system according to any one of claims 1-3, wherein the first end of the cylindrical shell extends at a non-perpendicular angle relative to the axis of the cylinder, wherein the cylinder and the aerosol generating device are configured such that when the cylinder is received in the cavity, a portion of the first end of the cylindrical shell abuts against the upstream end wall of the cavity, such that the first end of the cylindrical shell guides airflow from the cavity air inlet to the first side of the cylinder.

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