Heating element comprising an electrically conductive mesh

Abstract

A heater assembly (10) for an aerosol generation system is provided, the heater assembly (10) including a heating element (11). The heating element (11) includes a mesh (12) comprising a plurality of first filaments (20) extending in a first direction, wherein the first filaments (20) comprise a first material having a first electrical conductivity. The mesh (12) also includes a plurality of second filaments (22) extending in a second direction, wherein the first direction is perpendicular to the second direction, and wherein the second filaments (22) comprise a second material having a second electrical conductivity. The first electrical conductivity is greater than the second electrical conductivity. Each filament (20) includes a core and a coating covering the core. The coating comprises the first material, and the core of each filament (20) is formed of a material having a lower electrical conductivity than the first material. The heater assembly (10) also includes a first electrical terminal (13) and a second electrical terminal (15), each connected to at least one of the first filaments (20). During use, current is conducted between the first electrical terminal (13) and the second electrical terminal (15) via multiple second wires (22).

Description

Technical Field

[0001] This invention relates to a heating element for an aerosol generation system. More specifically, the invention relates to a heating element for an aerosol generation system comprising a first filament and a second filament extending in a first direction and a second direction. The first filament comprises a first material, and the second filament comprises a second material, wherein the first material has a greater electrical conductivity than the second material. The invention also relates to heater assemblies, cylinders, aerosol generation systems, and methods of forming a mesh. Background Technology

[0002] A handheld electrically operated aerosol generating apparatus and system are known, comprising: a device portion including a battery and control electronics; a portion for containing or receiving a liquid aerosol forming matrix; and an electrically operated heater for heating the aerosol forming matrix to generate an aerosol. The heater typically includes a coil wound around an elongated core that transfers the liquid aerosol forming matrix from a liquid storage compartment to the heater. Current can pass through the coil to heat the heater, thereby generating an aerosol from the aerosol forming matrix. In other devices, the heater may include a conductive mesh. A mouthpiece portion is also included, through which a user can inhale to draw the aerosol into their mouth.

[0003] Some electrical components of an aerosol generating apparatus (such as soldered electrical connections) may include tin. For example, an aerosol generating apparatus including a heater comprising a conductive mesh may include at least one tin electrode that extends across a portion of the mesh to distribute current across the wires of the mesh. However, when the aerosol generating apparatus is used with a liquid aerosol forming matrix including one or more acids, the tin component of the aerosol generating apparatus may corrode. Summary of the Invention

[0004] It is desirable to provide heating elements for aerosol generation systems that mitigate or overcome these problems of known aerosol generation devices.

[0005] According to this disclosure, a heating element for an aerosol generation system is provided, the heating element comprising a mesh. The mesh may include a plurality of first filaments extending in a first direction. The first filaments may include a first material having a first conductivity. The mesh may include a plurality of second filaments extending in a second direction. The first direction may be perpendicular to the second direction. The second filaments may include a second material having a second conductivity. The first conductivity may be greater than the second conductivity.

[0006] According to a first aspect of this disclosure, a heating element for an aerosol generation system is provided, the heating element comprising a mesh. The mesh includes a plurality of first filaments extending in a first direction, wherein the first filaments comprise a first material having a first conductivity. The mesh also includes a plurality of second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction. The second filaments comprise a second material having a second conductivity. The first conductivity is greater than the second conductivity.

[0007] Advantageously, the higher conductivity of the first material facilitates the distribution of current from the power source to the second wire via the first wire. Advantageously, the ease of current distribution to the second wire eliminates the need for electrodes on the mesh. For example, wires or other electrical contacts can be directly connected to one or more of the first wires. Advantageously, this eliminates the need for tin electrodes on the mesh heating element of known aerosol generating devices.

[0008] Advantageously, the lower conductivity of the second material facilitates resistive heating of the second wire when current is conducted through it.

[0009] In embodiments where the second filament is formed of a material having a positive temperature coefficient, hot spots that may form during operation of the heating element will result in regions of increased resistance in the second filament corresponding to these hot spots. Advantageously, the greater conductivity of the first material facilitates the distribution of current away from such regions of increased resistance in the second filament, which facilitates more uniform heating across the mesh.

[0010] Preferably, the first material has a density of approximately 8 × 10⁻⁶. 6 Siemens / meter and approximately 80×10 6 Conductivity between Siemens and meters.

[0011] Preferably, the second material has a density of approximately 0.8 × 10⁻⁶. 6 Siemens / meter and approximately 1.7 × 10 6 Conductivity between Siemens and meters.

[0012] Preferably, the first material includes at least one selected from silver, gold, platinum, aluminum, tin, and copper. Preferably, the first material includes at least one selected from silver, gold, and platinum. Preferably, the first material includes silver. Preferably, the first material is silver.

[0013] Each filament in the first filament may be formed from a first material. Each filament in the second filament may be formed from a second material.

[0014] Preferably, each filament of the first filament includes a core and a coating covering the core. Preferably, the coating comprises a first material. Advantageously, providing each filament of the first filament with a coating comprising the first material can provide the first filament with a greater electrical conductivity than the second filament. Advantageously, the core of each filament of the first filament can be formed of a material with lower electrical conductivity, which can reduce or minimize the cost of each filament of the first filament.

[0015] The coating of each filament in the first filament may have a thickness of at least about 1 micrometer, at least about 2 micrometers, at least about 3 micrometers, or at least about 4 micrometers. The coating of each filament in the first filament may have a thickness of less than about 5 micrometers, less than about 4 micrometers, less than about 3 micrometers, or less than about 2 micrometers. Preferably, the coating of each filament in the first filament may have a thickness between about 1 micrometer and about 5 micrometers, more preferably between about 2 micrometers and about 5 micrometers, even more preferably between about 2 micrometers and about 4 micrometers, and even more preferably between about 3 micrometers and about 4 micrometers.

[0016] The coating can be formed by at least one of the following processes: spraying, chemical vapor deposition, and physical vapor deposition.

[0017] The core of each filament in the first filament may include a metal alloy. 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 steel, Iron-aluminum based alloys and iron-manganese-aluminum based alloys. It is a registered trademark of Titanium Metals Company. Preferably, the core of each wire in the first wire comprises stainless steel, more preferably 300 series stainless steel, such as AISI 304, 316, 304L, 316L.

[0018] In a particularly preferred embodiment, each filament in the first filament comprises a core containing AISI 304 stainless steel and a coating containing silver.

[0019] The second material may include metal alloys. 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; and nickel-, iron-, and cobalt-based superalloys, stainless steel, Iron-aluminum based alloys and iron-manganese-aluminum based alloys. "[Illegible]" is a registered trademark of Titanium Metals. Preferably, the second material comprises stainless steel, more preferably 300 series stainless steel, such as AISI 304, 316, 304L, 316L. In a particularly preferred embodiment, the second material comprises AISI 304 stainless steel.

[0020] The core of each filament in the first filament may include a material different from the second material.

[0021] The core of each filament in the first filament may also include a second material. Preferably, the core of each filament in the first filament and the core of each filament in the second filament include stainless steel, more preferably 300 series stainless steel, such as AISI 304, 316, 304L, 316L. In a particularly preferred embodiment, the core of each filament in the first filament and the core of each filament in the second filament includes AISI 304 stainless steel.

[0022] The net can be woven or nonwoven. Preferably, the net is woven.

[0023] The first filament can extend in the weft direction, and the second filament can extend in the warp direction.

[0024] The filaments can define a gap between the first and second filaments, and the gap can have a width between about 10 micrometers and about 100 micrometers. Preferably, the width of the gap causes capillary action in the gap, such that during use, the liquid aerosol forming matrix to be vaporized is drawn into the gap, thereby increasing the contact area between the heating element and the liquid aerosol forming matrix.

[0025] The first and second filaments can form a web density between approximately 60 and approximately 240 filaments per centimeter (+ / - 10%). Preferably, the web density is between approximately 100 and approximately 140 filaments per centimeter (+ / - 10%). More preferably, the web density is approximately 115 filaments per centimeter. The width of the gaps can be between approximately 20 micrometers and approximately 300 micrometers, preferably between approximately 50 micrometers and approximately 100 micrometers, and more preferably approximately 70 micrometers. The percentage of the open area of ​​the web, which is the ratio of the area of ​​the gaps to the total area of ​​the web, can be between approximately 40% and approximately 90%, preferably between approximately 85% and approximately 80%, and more preferably approximately 82%.

[0026] The width or diameter of each of the first and second filaments may be between about 10 micrometers and about 100 micrometers, preferably between about 10 micrometers and about 50 micrometers, more preferably between about 12 micrometers and about 25 micrometers, and most preferably about 16 micrometers. Each of the first and second filaments may have a circular cross-section or a flat cross-section.

[0027] The area of ​​the mesh may be small, for example, less than or equal to about 50 square millimeters, preferably less than or equal to about 25 square millimeters, more preferably about 15 square millimeters. Preferably, the area of ​​the mesh facilitates the integration of the heating element into the handheld system. Advantageously, setting the mesh size to an area of ​​less than or equal to about 50 square millimeters reduces the total power required to heat the mesh while still ensuring sufficient contact between the mesh and the liquid aerosol forming matrix. The mesh can be square. The mesh can be rectangular. The length of the mesh can be between about 2 mm and about 10 mm. The width of the mesh can be between about 2 mm and about 10 mm. Preferably, the mesh has dimensions of about 5 mm by 3 mm.

[0028] Preferably, the mesh is substantially flat. Advantageously, a substantially flat mesh facilitates the simple manufacture of the heating element and the aerosol generation system including the heating element. Geometrically, the term "substantially flat" is used to refer to a mesh that takes the form of a substantially two-dimensional topological manifold. In some instances, the substantially flat mesh may extend substantially along a surface in two dimensions rather than in a third dimension. In some instances, the dimensions of the substantially flat mesh in the two dimensions within the surface may be at least five times larger than the dimensions in the third dimension perpendicular to said surface. In some instances, the substantially flat mesh may define two imaginary substantially parallel flat surfaces. In some instances, the substantially flat mesh may be a structure between two imaginary substantially parallel flat surfaces, wherein the distance between the two imaginary surfaces is substantially less than the in-plane extension. In some instances, only one of the two imaginary substantially parallel surfaces may be flat. In some instances, the substantially flat mesh may be planar. In other instances, the substantially flat mesh may be curved along one or more dimensions, for example, forming an arch or bridge shape.

[0029] According to this disclosure, a heating element for an aerosol generation system is provided, the heating element comprising a mesh. The mesh may include a plurality of first filaments extending in a first direction. Each of the first filaments may include at least one of silver, gold, and platinum. The mesh may include a plurality of second filaments extending in a second direction. The first direction may be perpendicular to the second direction. Each of the second filaments may include stainless steel.

[0030] According to a second aspect of this disclosure, a heating element for an aerosol generation system is provided, the heating element comprising a mesh. The mesh includes a plurality of first filaments extending in a first direction, wherein each of the first filaments comprises at least one of silver, gold, and platinum. The mesh also includes a plurality of second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction. Each of the second filaments comprises stainless steel.

[0031] Each wire in the first filament may be formed from at least one of silver, gold, and platinum. Each wire in the first filament may be formed from silver.

[0032] Preferably, each filament in the first filament includes a core and an overlying coating, wherein the coating includes at least one of silver, gold, and platinum. Preferably, the coating includes silver.

[0033] Preferably, the core of each filament in the first filament comprises stainless steel, more preferably 300 series stainless steel, such as AISI 304, 316, 304L, 316L. In a particularly preferred embodiment, each filament in the first filament comprises a core containing AISI 304 stainless steel.

[0034] Preferably, each wire in the second wire comprises 300 series stainless steel, such as AISI 304, 316, 304L, 316L. In a particularly preferred embodiment, each wire in the second wire comprises AISI 304 stainless steel.

[0035] The heating element may include any of the optional or preferred features described with respect to the first aspect of this disclosure.

[0036] According to a third aspect of this disclosure, a heater assembly for an aerosol generation system is provided. According to any of the embodiments described herein, the heater assembly includes a heating element according to a first or second aspect of this disclosure. The heater assembly further includes at least two electrical terminals for supplying electricity to the heating element, wherein each of the electrical terminals is electrically connected to at least one of the first wires.

[0037] Preferably, each of the electrical terminals is directly connected to at least one of the first wires. Advantageously, directly connecting the electrical terminals to at least one of the first wires reduces the number of components required to manufacture the heater assembly. For example, directly connecting the electrical terminals to at least one of the first wires eliminates the need for one or more electrical contact pads for the heating element, which are typically formed of tin in known aerosol generating apparatuses.

[0038] Preferably, each of the electrical terminals is directly electrically connected to at least one of the first wires by mechanically biasing each of the electrical terminals against a portion of the mesh. Each of the electrical terminals may be a spring terminal.

[0039] Each of the electrical terminals may include brass. Preferably, each of the electrical terminals includes a substrate material and a coating covering the substrate material, wherein the coating includes a first material. Advantageously, providing each of the electrical terminals with a coating comprising the same material as the first wire facilitates improved electrical connection between each electrical terminal and the first wire contacting the electrical terminal. Advantageously, providing each of the electrical terminals with a coating comprising the same material as the first wire reduces or prevents current corrosion. The substrate material may include brass. The coating may include at least one of silver, gold, platinum, aluminum, tin, and copper. Preferably, the coating includes at least one of silver, gold, and platinum. Preferably, the coating includes silver. Preferably, the coating is silver.

[0040] The heater assembly may further include a heater assembly housing, wherein a heating element and at least two electrical terminals are mounted on the heater assembly housing. The heater assembly housing may include a first housing portion on which the heating element is mounted and a second housing portion on which at least two electrical terminals are mounted. Preferably, the first housing portion is arranged to connect to the second housing portion. Preferably, the first housing portion is arranged to connect to the second housing portion by an interference fit. Preferably, when the first housing portion is connected to the second housing portion, at least two electrical terminals are mechanically biased against a mesh.

[0041] The heater assembly housing may comprise any suitable material or combination of materials. Preferably, the heater assembly housing is formed of a plastic or thermoplastic suitable for food or pharmaceutical applications. For example, the heater assembly housing may comprise at least one of polypropylene, polyetheretherketone (PEEK), and polyethylene. Preferably, the material is lightweight and non-brittle.

[0042] The heater assembly may also include a conveying material for delivering a liquid aerosol forming matrix to the heating element. Preferably, the conveying material includes a first end in contact with a mesh of the heating element. The conveying material may include a capillary material. The conveying material may include a capillary wick. The conveying material may include ceramics. The ceramics may include at least one of alumina, zirconium oxide, and hydroxyapatite.

[0043] In embodiments where the heater assembly includes a heater assembly housing, at least a portion of the conveyed material can be received within the heater assembly housing. The conveyed material can be secured within the heater assembly housing via an interference fit.

[0044] The conveying material can be formed by directly depositing material onto the mesh of the heating element. Alternatively, the conveying material can be formed by directly depositing ceramic onto the mesh of the heating element. The ceramic may include at least one of alumina, zirconium oxide, and hydroxyapatite.

[0045] According to a fourth aspect of this disclosure, a cylinder for an aerosol generation system is provided according to any of the embodiments described herein, the cylinder including a heater assembly according to a third aspect of this disclosure. The cylinder also includes a liquid storage compartment for holding a liquid aerosol forming matrix.

[0046] As used herein, the term "aerosol" refers to a dispersion of solid particles or droplets, or a combination of solid particles and droplets, in a gas. Aerosols can be visible or invisible. Aerosols can include vapors of substances that are typically liquid or solid at room temperature, as well as solid particles or droplets, or a combination of solid particles and droplets.

[0047] As used herein, the term "aerosol-forming matrix" refers to a matrix capable of releasing volatile compounds that can form aerosols. Volatile compounds can be released by heating or burning the aerosol-forming matrix.

[0048] In embodiments where the heater assembly includes a heater assembly housing, the heater assembly housing may define at least a portion of a liquid storage compartment.

[0049] The liquid storage compartment may include a first storage section and a second storage section that are in communication with each other. The first storage section of the liquid storage compartment may be located on the side of the heater assembly opposite to the second storage section of the liquid storage compartment. The liquid aerosol forming matrix may be contained in both the first and second storage sections of the liquid storage compartment.

[0050] Advantageously, the first storage portion of the storage compartment is larger than the second storage portion of the liquid storage compartment. The cartridge can be configured to allow a user to suction or suck on the cartridge to inhale the aerosol generated within it. In use, the nozzle opening of the cartridge is typically positioned above the heater assembly, with the first storage portion of the storage compartment positioned between the nozzle opening and the heater assembly. Making the first storage portion of the liquid storage compartment larger than the second storage portion ensures that, under the influence of gravity, liquid is delivered from the first storage portion to the second storage portion of the liquid storage compartment.

[0051] The cylinder may have an opening and a connecting end, through which a user can draw in the generated aerosol, and the connecting end is configured to connect to an aerosol generating device. Preferably, a first side of the heating element faces the opening, and a second side of the heating element faces the connecting end.

[0052] In embodiments where the heater assembly includes a conveying material, the conveying material is preferably in fluid communication with a liquid storage compartment. Preferably, the conveying material is in fluid communication with a second storage portion of the liquid storage compartment. Preferably, a second end of the conveying material is located within the second storage portion of the liquid storage compartment.

[0053] The cylinder may define a closed airflow passage from an air inlet, through a first side of the heater assembly, to an opening at the end of the cylinder. The closed airflow passage may pass through a first or second storage portion of the liquid storage compartment. In one embodiment, the airflow passage extends between the first and second storage portions of the liquid storage compartment. Alternatively, the airflow passage may extend through the first storage portion of the liquid storage compartment. At least a portion of the first storage portion of the liquid storage compartment may have an annular cross-section, wherein at least a portion of the airflow passage extends from the air inlet, through the heater assembly, through the first storage portion of the liquid storage compartment, to the opening at the end. At least a portion of the airflow passage may extend from the heater assembly to the opening at the end adjacent to the first storage portion of the liquid storage compartment.

[0054] The cartridge may contain a retaining material for holding the liquid aerosol forming matrix. The retaining material may be in a first storage portion of the liquid storage compartment, a second storage portion of the liquid storage compartment, or both. The retaining material may be a foam, sponge, or fiber assembly. The retaining material may be formed from a polymer or copolymer. The retaining material may be a spun polymer. The liquid aerosol forming matrix may be released into the retaining material during use. For example, the liquid aerosol forming matrix may be contained within a capsule.

[0055] The container advantageously contains a liquid aerosol forming matrix within a liquid storage compartment. The liquid aerosol forming matrix may include nicotine. The nicotine comprising the liquid aerosol forming matrix may be a nicotine salt matrix. The liquid aerosol forming matrix may include plant-based materials. The liquid aerosol forming matrix may include tobacco. The liquid aerosol forming matrix may include tobacco-containing materials containing volatile tobacco flavor compounds, said materials being released from the aerosol forming matrix upon heating. The liquid aerosol forming matrix may include homogenized tobacco material. The liquid aerosol forming matrix may include tobacco-free materials. The liquid aerosol forming matrix may include homogenized plant-based materials.

[0056] Liquid aerosol forming matrix may include one or more aerosol forming agents. An aerosol forming agent is any suitable known compound or mixture of compounds that, in use, facilitates the formation of a dense and stable aerosol and is substantially resistant to thermal degradation at the system's operating temperature. Examples of suitable aerosol forming agents include glycerol and propylene glycol. Suitable aerosol forming agents are well known in the art and include, but are not limited to: polyols, such as triethylene glycol, 1,3-butanediol, and glycerol; esters of polyols, such as mono, di, or triacetic acids of glycerol; and aliphatic esters of mono, di, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate. Liquid aerosol forming matrix may include water, solvents, ethanol, plant extracts, and natural or artificial flavorings.

[0057] The liquid aerosol forming matrix may include nicotine and at least one aerosol forming agent. The aerosol forming agent may be glycerol or propylene glycol. The liquid aerosol forming matrix may have a nicotine concentration between about 0.5% and about 10%, for example, about 2%.

[0058] The cylinder may include a housing. The housing may be formed of a moldable plastic material, such as polypropylene (PP) or polyethylene terephthalate (PET). The housing may form part or all of the walls of one or both sections of the liquid storage compartment. The housing and the liquid storage compartment may be formed integrally. Alternatively, the liquid storage compartment may be formed separately from the housing and assembled to the housing.

[0059] According to a fifth aspect of this disclosure, an aerosol generation system comprising a cylinder according to a fourth aspect of this disclosure is provided, according to any of the embodiments described herein. The aerosol generation system further includes an aerosol generation device arranged to be removably coupled to the cylinder. The aerosol generation device includes a power source for supplying electricity to a heating element.

[0060] The aerosol generating apparatus may include a control circuit system configured to control the power supply from a power source to a heating element.

[0061] The control circuitry may include a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller, an application-specific integrated circuit (ASIC), or other circuitry capable of providing control. The control circuitry may also include other electronic components. For example, in some embodiments, the control circuitry may include any of a sensor, a switch, or a display element. Power may be continuously supplied to the heating element after the aerosol generating device is activated, or it may be supplied intermittently, such as on a per-pocket suction basis. Power may be supplied to the heating element in the form of current pulses, for example, by means of pulse width modulation (PWM).

[0062] The power source can be a DC power source. The power source can be a battery. The battery can be a lithium-based battery, such as lithium cobalt, lithium iron phosphate, lithium titanate, or lithium polymer batteries. The battery can be a nickel-metal hydride battery or a nickel-cadmium battery. The power source can be another form of charge storage device, such as a capacitor. The power source can be rechargeable and configured for many charge-discharge cycles. The power source can have a capacity that allows storing enough energy for one or more user experiences; for example, the power source can have sufficient capacity to allow continuous aerosol generation for approximately six minutes, corresponding to the typical time required to smoke a regular cigarette, or for a multiple of six minutes. In another example, the power source can have sufficient capacity to allow a predetermined number of puffs or discontinuous activation of the heating element.

[0063] The aerosol generating device may include a housing. The housing may be elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites containing one or more of those materials, or thermoplastic materials suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene. Preferably, the material is lightweight and non-brittle.

[0064] The aerosol generating system can be a handheld aerosol generating system. It is configured to allow the user to inhale through the mouthpiece to draw in the aerosol. The aerosol generating system can have a size comparable to a conventional cigar or cigarette. The aerosol generating system can have an overall length between approximately 30 mm and approximately 150 mm. The aerosol generating system can have an outer diameter between approximately 5 mm and approximately 30 mm.

[0065] According to this disclosure, a method is provided for forming a mesh for use as a heating element in an aerosol generation system. The method may include providing a plurality of first filaments. The plurality of first filaments may comprise a first material having a first electrical conductivity. The method may include providing a plurality of second filaments. The plurality of second filaments may comprise a second material having a second electrical conductivity. The first electrical conductivity may be greater than the second electrical conductivity. The method may include forming a mesh comprising a plurality of first filaments extending in a first direction and a plurality of second filaments extending in a second direction. The first direction may be perpendicular to the second direction.

[0066] According to a sixth aspect of this disclosure, a method is provided for forming a mesh for use as a heating element in an aerosol generation system. The method includes providing a plurality of first filaments comprising a first material having a first electrical conductivity. The method further includes providing a plurality of second filaments comprising a second material having a second electrical conductivity, wherein the first electrical conductivity is greater than the second electrical conductivity. The method further includes forming a mesh comprising a plurality of first filaments extending in a first direction and a plurality of second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction.

[0067] According to any of the embodiments described herein, a network formed by the method according to the sixth aspect of this disclosure may be a network according to the first aspect of this disclosure. A network formed by the method according to the sixth aspect of this disclosure may include any of the optional or preferred features described with respect to the first aspect of this disclosure.

[0068] Preferably, the method further includes heat-treating the mesh to bond the plurality of first filaments to the plurality of second filaments. Advantageously, bonding the plurality of first filaments to the plurality of second filaments reduces the resistance at the contact points between the plurality of first filaments and the plurality of second filaments.

[0069] The steps of forming a web may include weaving multiple first filaments and multiple second filaments to form a woven web. The first filaments may extend in the weft direction, and the second filaments may extend in the warp direction.

[0070] According to this disclosure, a method is provided for forming a mesh for use as a heating element in an aerosol generation system. The method may include providing a plurality of first filaments. Each of the first filaments may include at least one of silver, gold, and platinum. The method may include providing a plurality of second filaments. Each of the second filaments may include stainless steel. The method may include forming a mesh comprising a plurality of first filaments extending in a first direction and a plurality of second filaments extending in a second direction. The first direction may be perpendicular to the second direction.

[0071] According to a seventh aspect of this disclosure, a method is provided for forming a mesh for use as a heating element in an aerosol generation system. The method includes providing a plurality of first filaments, wherein each of the first filaments comprises at least one of silver, gold, and platinum. The method further includes providing a plurality of second filaments, wherein each of the second filaments comprises stainless steel. The method further includes forming a mesh comprising a plurality of first filaments extending in a first direction and a plurality of second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction.

[0072] Each wire in the first filament may be formed from at least one of silver, gold, and platinum. Each wire in the first filament may be formed from silver.

[0073] Preferably, each filament in the first filament includes a core and an overlying coating, wherein the coating includes at least one of silver, gold, and platinum. Preferably, the coating includes silver.

[0074] Preferably, the core of each filament in the first filament comprises stainless steel, more preferably 300 series stainless steel, such as AISI 304, 316, 304L, 316L. In a particularly preferred embodiment, each filament in the first filament comprises a core containing AISI 304 stainless steel.

[0075] Preferably, each wire in the second wire comprises 300 series stainless steel, such as AISI 304, 316, 304L, 316L. In a particularly preferred embodiment, each wire in the second wire comprises AISI 304 stainless steel.

[0076] According to any of the embodiments described herein, a network formed by the method according to the seventh aspect of this disclosure may be a network according to the first aspect of this disclosure. A network formed by the method according to the seventh aspect of this disclosure may include any of the optional or preferred features described with respect to the first aspect of this disclosure.

[0077] According to any of the embodiments described herein, the network formed by the method of the seventh aspect of this disclosure may be a network according to the second aspect of this disclosure. The network formed by the method of the seventh aspect of this disclosure may include any of the optional or preferred features described with respect to the second aspect of this disclosure.

[0078] Preferably, the method further includes heat-treating the mesh to bond the plurality of first filaments to the plurality of second filaments. Advantageously, bonding the plurality of first filaments to the plurality of second filaments reduces the resistance at the contact points between the plurality of first filaments and the plurality of second filaments.

[0079] The steps of forming a web may include weaving multiple first filaments and multiple second filaments to form a woven web. The first filaments may extend in the weft direction, and the second filaments may extend in the warp direction.

[0080] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0081] Example Ex1: A heating element for an aerosol generation system, the heating element comprising a mesh, the mesh comprising:

[0082] A plurality of first filaments extending in a first direction, wherein the first filaments comprise a first material having a first electrical conductivity;

[0083] Multiple second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction, and wherein the second filaments comprise a second material having a second conductivity; and

[0084] The first conductivity is greater than the second conductivity.

[0085] Example Ex2: The heating element according to Example Ex1, wherein each of the first wires includes a core and a coating covering the core.

[0086] Example Ex3: The heating element according to Example Ex2, wherein the coating comprises the first material.

[0087] Example Ex4: The heating element according to Example Ex2 or Ex3, wherein the core comprises stainless steel.

[0088] Example Ex5: A heating element according to any one of Examples Ex2 to Ex4, wherein the coating has a thickness between 1 micrometer and 5 micrometers.

[0089] Example Ex6: A heating element according to any one of Examples Ex2 to Ex5, wherein the core of each filament in the first filament comprises the same material as each filament in the second filament.

[0090] Example Ex7: The heating element according to any of the preceding examples, wherein the coating comprises at least one of silver, gold and platinum.

[0091] Example Ex8: The heating element according to any of the preceding examples, wherein each of the second wires comprises stainless steel.

[0092] Example Ex9: The heating element according to any of the preceding examples, wherein the mesh is a woven mesh.

[0093] Example Ex10: A heater assembly for an aerosol generation system, the heater assembly comprising:

[0094] Heating element according to any of the foregoing examples; and

[0095] At least two electrical terminals for supplying power to the heating element, wherein each of the electrical terminals is connected to at least one of the first wires.

[0096] Example Ex11: The heater assembly according to Example Ex10 further includes a conveying material for conveying a liquid aerosol forming matrix to the heating element.

[0097] Example Ex12: A cylinder for an aerosol generation system, the cylinder comprising:

[0098] The heater assembly according to Example Ex10 or Ex11; and

[0099] Liquid storage compartments used to hold liquid aerosols forming a matrix.

[0100] Example Ex13: An aerosol generation system, the aerosol generation system comprising:

[0101] Based on the cylinder in Example Ex12; and

[0102] An aerosol generating device is arranged to be removably coupled to the cylinder, the aerosol generating device including a power source for supplying power to the heating element.

[0103] Example Ex14: A method for forming a mesh for use as a heating element in an aerosol generation system, the method comprising:

[0104] Provide multiple first filaments comprising a first material having a first electrical conductivity;

[0105] Provided are a plurality of second filaments comprising a second material having a second conductivity, wherein the first conductivity is greater than the second conductivity; and

[0106] A web is formed, the web comprising a plurality of first filaments extending in a first direction and a plurality of second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction.

[0107] Example Ex15: The method according to Example Ex14 further includes heat-treating the net to bond the plurality of first filaments to the plurality of second filaments.

[0108] Example Ex16: According to the method of Example Ex14 or Ex15, each filament in the first filament includes a core and a coating covering the core.

[0109] Example Ex17: According to the method of Example Ex16, the coating comprises the first material.

[0110] Example Ex18: According to the method of Example Ex16 or Ex17, the core comprises stainless steel.

[0111] Example Ex19: The method according to any one of Examples Ex16 to Ex18, wherein the coating has a thickness between 1 micrometer and 5 micrometers.

[0112] Example Ex20: The method according to any one of Examples Ex16 to Ex19, wherein the core of each filament in the first filament comprises the same material as each filament in the second filament.

[0113] Example Ex21: The method according to any one of Examples Ex16 to Ex20, wherein the coating comprises at least one of silver, gold and platinum.

[0114] Example Ex22: The method according to any one of Examples Ex14 to Ex21, wherein the second material includes stainless steel.

[0115] Example Ex23: The method according to any one of Examples Ex14 to Ex22, wherein forming a web includes weaving the plurality of first filaments with the plurality of second filaments to form a woven web.

[0116] Example Ex24: A heating element for an aerosol generation system, the heating element comprising a mesh, the mesh comprising:

[0117] A plurality of first filaments extending in a first direction, wherein each of the first filaments comprises at least one of silver, gold, and platinum; and

[0118] Multiple second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction, and wherein each of the second filaments comprises stainless steel.

[0119] Example Ex25: The heating element according to Example Ex24, wherein each of the first wires is formed of at least one of silver, gold and platinum.

[0120] Example Ex26: The heating element according to Example Ex24, wherein each of the first wires is formed of silver.

[0121] Example Ex27: The heating element according to Example Ex24, wherein each of the first wires includes a core and a coating covering the core.

[0122] Example Ex28: The heating element according to Example Ex27, wherein the core comprises stainless steel.

[0123] Example Ex29: The heating element according to Example Ex27 or Ex28, wherein the coating comprises at least one of silver, gold and platinum.

[0124] Example Ex30: The heating element according to Example Ex29, wherein the coating comprises silver.

[0125] Example Ex31: The heating element according to Example Ex27 or Ex28, wherein the coating is formed of at least one of silver, gold and platinum.

[0126] Example Ex32: The heating element according to Example Ex31, wherein the coating is formed of silver.

[0127] Example Ex33: A heating element according to any one of Examples Ex27 to Ex32, wherein the coating has a thickness between 1 micrometer and 5 micrometers.

[0128] Example Ex34: A heating element according to any one of Examples Ex24 to Ex33, wherein the mesh is a woven mesh.

[0129] Example Ex35: A heater assembly for an aerosol generation system, the heater assembly comprising:

[0130] Heating element according to any one of Examples Ex24 to Ex34; and

[0131] At least two electrical terminals for supplying power to the heating element, wherein each of the electrical terminals is connected to at least one of the first wires.

[0132] Example Ex36: The heater assembly according to Example Ex35 further includes a conveying material for conveying a liquid aerosol forming matrix to the heating element.

[0133] Example Ex37: A cylinder for an aerosol generation system, the cylinder comprising:

[0134] The heater assembly according to Example Ex35 or Ex36; and

[0135] Liquid storage compartments used to hold liquid aerosols forming a matrix.

[0136] Example Ex38: An aerosol generation system, the aerosol generation system comprising:

[0137] Based on the cylinder of Example Ex37; and

[0138] An aerosol generating device is arranged to be removably coupled to the cylinder, the aerosol generating device including a power source for supplying power to the heating element.

[0139] Example Ex39: A method for forming a mesh for use as a heating element in an aerosol generation system, the method comprising:

[0140] Provide multiple first filaments, wherein each of the first filaments comprises at least one of silver, gold, and platinum;

[0141] Provide multiple second wires, wherein each of the second wires comprises stainless steel; and

[0142] A web is formed, the web comprising a plurality of first filaments extending in a first direction and a plurality of second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction.

[0143] Example Ex40: The method according to Example Ex39 further includes heat-treating the mesh to bond the plurality of first filaments to the plurality of second filaments.

[0144] Example Ex41: According to the method of Example Ex39 or Ex40, each of the first wires is formed of at least one of silver, gold and platinum.

[0145] Example Ex42: According to the method of Example Ex41, each of the first wires is formed of silver.

[0146] Example Ex43: According to the method of Example Ex39 or Ex40, each filament in the first filament includes a core and a coating covering the core.

[0147] Example Ex44: According to the method of Example Ex43, the core comprises stainless steel.

[0148] Example Ex45: According to the method of Example Ex43 or Ex44, the coating comprises at least one of silver, gold and platinum.

[0149] Example Ex46: According to the method of Example Ex45, the coating includes silver.

[0150] Example Ex47: According to the method of Example Ex43 or Ex44, the coating is formed from at least one of silver, gold and platinum.

[0151] Example Ex48: According to the method of Example Ex47, the coating is formed of silver.

[0152] Example Ex49: The method according to any one of Examples Ex39 to Ex48, wherein the coating has a thickness between 1 micrometer and 5 micrometers.

[0153] Example Ex50: The method according to any one of Examples Ex39 to Ex49, wherein forming a web includes weaving the plurality of first filaments with the plurality of second filaments to form a woven web. Attached Figure Description

[0154] Several examples will now be described further with reference to the accompanying drawings, in which:

[0155] Figure 1 This is a schematic perspective view of a heater assembly according to an example of this disclosure;

[0156] Figure 2 It is along Figure 1 The line 1-1 in the middle is cut off Figure 1 A schematic side section view of the heater assembly;

[0157] Figure 3 This is a schematic side cross-sectional view of an exemplary aerosol generation system, which includes a cylinder and an aerosol generation device; and

[0158] Figure 4 It is a 90-degree rotation around the longitudinal axis of the aerosol generation system. Figure 3 A schematic side cross-sectional view of the aerosol generation system. Detailed Implementation

[0159] Reference Figure 1 The image shows a heater assembly 10, which includes a heating element 11, a ceramic transfer material 14, a first electrical terminal 13, and a second electrical terminal 15. Figure 2 The heater assembly 10 is shown along Figure 1 The section view of line 1-1.

[0160] The heating element 11 includes a conductive mesh 12. The mesh 12 is woven and includes a plurality of first filaments 20 extending in a first direction and a plurality of second filaments 22 extending in a second direction perpendicular to the first direction. Each of the second filaments 22 is formed of stainless steel. Each of the first filaments 20 is formed of a stainless steel core and a coating formed of silver covering the core. The silver coating of each of the first filaments 20 has a higher electrical conductivity than the stainless steel forming each of the second filaments 22.

[0161] The first electrical terminal 13 and the second electrical terminal 15, used to supply current to the mesh 12, are formed of brass and are arranged on opposite sides of the mesh 12. Each of the first electrical terminal 13 and the second electrical terminal 15 includes two contact portions 24, each of which is biased against several wires of the first wire 20. The higher conductivity of the silver coating of the first wire 20 facilitates the distribution of current from the first electrical terminal 13 and the second electrical terminal 15 to a plurality of second wires 22 via the first wire 20. During use, current is conducted between the first electrical terminal 13 and the second electrical terminal 15 via the plurality of second wires 22. The lower conductivity of the second wires 22 facilitates resistive heating of the second wires 22 as current flows through them.

[0162] Ceramic conveying material 14 is in direct contact with mesh 12 and is arranged to deliver a liquid aerosol forming matrix to mesh 12. A plurality of voids 16 are defined between a first filament 20 and a second filament 22 of mesh 12. During heating, vaporized aerosol forming matrix is ​​released from heater assembly 10 through voids 16 to generate an aerosol.

[0163] Figure 3 This is a schematic cross-sectional view of an exemplary aerosol generation system. Figure 4 The same cross-sectional view is shown, in which the aerosol generation system is rotated 90 degrees about its longitudinal axis.

[0164] The aerosol generating system comprises two main components: a cartridge 100 and an aerosol generating device 200. A connecting end 115 of the cartridge 100 is removably connected to a corresponding connecting end 205 of the aerosol generating device 200. Both the connecting end 115 of the cartridge 100 and the connecting end 205 of the aerosol generating device 200 have electrical contacts or connections (not shown) arranged to cooperate in providing an electrical connection between the cartridge 100 and the aerosol generating device 200. The aerosol generating device 200 includes a power supply 210 in the form of a battery and a control circuitry system 220; in this example, the battery is a rechargeable lithium-ion battery. The aerosol generating system is portable and has a size equivalent to that of a conventional cigar or cigarette. A mouthpiece 125 is disposed at the end of the cartridge 100 opposite the connecting end 115.

[0165] Cylinder 100 includes Figure 1 and Figure 2 The heater assembly 10 includes a cylindrical shell 105 and a liquid storage compartment having a first storage portion 130 and a second storage portion 135. The liquid aerosol forming matrix is ​​held within the liquid storage compartment. Figure 4 As shown, a first storage portion 130 of the liquid storage compartment is connected to a second storage portion 135 of the liquid storage compartment by an annular portion of the first storage portion 130. Therefore, the liquid aerosol forming matrix in the first storage portion 130 can be transferred to the second storage portion 135. The heater assembly 10 receives liquid from the second storage portion 135 of the liquid storage compartment. At least a portion of the ceramic delivery material 14 of the heater assembly 10 extends into the second storage portion 135 of the liquid storage compartment to contact the liquid aerosol forming matrix therein.

[0166] Airflow passages 140 and 145 extend from an air inlet 150 formed in one side of the cylindrical shell 105 through the mesh 12 of the heater assembly 10 through the cylinder 100, and from the heater assembly 10 to a mouthpiece opening 110 formed in the cylindrical shell 105 at the end of the cylinder 100 opposite to the connecting end 115.

[0167] The components of the cylinder 100 are arranged such that a first storage portion 130 of the liquid storage compartment is located between the heater assembly 10 and the mouthpiece opening 110, and a second storage portion 135 of the liquid storage compartment is located on the side of the heater assembly 10 opposite to the mouthpiece opening 110. In other words, the heater assembly 10 is located between the first portion 130 and the second portion 135 of the liquid storage compartment and receives liquid from the second storage portion 135. The first storage portion 130 of the liquid storage compartment is closer to the mouthpiece opening 110 than the second storage portion 135. Airflow passages 140, 145 pass through the mesh 12 of the heater assembly 10 and extend between the first portion 130 and the second portion 135 of the liquid storage compartment.

[0168] The aerosol generation system is configured such that a user can inhale or puff through the mouthpiece 125 of the cartridge to draw aerosol into their mouth through the mouthpiece opening 110. In operation, when the user inhales through the mouthpiece 125, air is drawn from the air inlet 150 through the airflow passages 140, 145, past the heater assembly 10, and into the mouthpiece opening 110. When the system is activated, the control circuitry 220 controls the power supply 210 to the cartridge 100. This, in turn, controls the amount and nature of the vapor produced by the heater assembly 10. The control circuitry 220 may include an airflow sensor (not shown), and when the airflow sensor detects that the user is inhaling, the control circuitry 220 may supply power to the heater assembly 10. This type of control arrangement has long been used in aerosol generation systems such as inhalers and electronic cigarettes. When the user puffs through the mouthpiece opening 110 of the cartridge 100, the heater assembly 10 is activated and vapor is generated, which is entrained in the airflow passing through the airflow passages 140. The vapor is cooled within the airflow in passage 145 to form an aerosol, which is then drawn into the user's mouth through mouthpiece opening 110.

[0169] In operation, the mouthpiece opening 110 is typically the highest point of the system. The construction of the cylinder 100, and particularly the arrangement of the heater assembly 10 between the first storage portion 130 and the second storage portion 135 of the liquid storage compartment, is advantageous because it utilizes gravity to ensure that the liquid aerosol forming matrix is ​​delivered to the heater assembly 10, even when the liquid storage compartment is empty, while preventing excessive liquid supply to the heater assembly 10, which could lead to liquid leakage into the airflow passage 140.

Claims

1. A heater assembly for an aerosol generation system, the heater assembly comprising: Heating element, the heating element including a mesh, the mesh including: A plurality of first filaments extending in a first direction, wherein the first filaments comprise a first material having a first electrical conductivity; Multiple second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction, and wherein the second filaments comprise a second material having a second conductivity; and Wherein the first conductivity is greater than the second conductivity; Each of the first filaments includes a core and a coating covering the core; The coating comprises the first material, and the core of each filament in the first filament is formed of a material having a lower conductivity than the first material; and At least two electrical terminals for supplying power to the heating element; Each of the electrical terminals is connected to at least one of the first wires; The at least two electrical terminals include a first electrical terminal and a second electrical terminal; and During use, current is conducted between the first electrical terminal and the second electrical terminal via the plurality of second wires.

2. The heater assembly of claim 1, wherein the core comprises stainless steel.

3. The heater assembly of claim 1, wherein the coating has a thickness between 1 micrometer and 5 micrometers.

4. The heater assembly of claim 1, wherein the core of each filament in the first filament comprises the same material as each filament in the second filament.

5. The heater assembly of claim 1, wherein the first material comprises at least one of silver, gold, and platinum.

6. The heater assembly of claim 1, wherein the second material comprises stainless steel.

7. The heater assembly of claim 1, wherein the mesh is a woven mesh.

8. The heater assembly of claim 1, further comprising a transport material for conveying a liquid aerosol forming matrix to the heating element.

9. A cylinder for an aerosol generation system, the cylinder comprising: The heater assembly according to any of the preceding claims; as well as Liquid storage compartments used to hold liquid aerosols forming a matrix.

10. An aerosol generation system, the aerosol generation system comprising: The cylinder according to claim 9; as well as An aerosol generating device is arranged to be removably coupled to the cylinder, the aerosol generating device including a power supply for supplying power to the heating element.

11. A method of forming a heater assembly for an aerosol generation system, the method comprising: A mesh is formed to serve as a heating element, the mesh comprising: Provided are a plurality of first filaments comprising a first material having a first conductivity, wherein each of the first filaments comprises a core and a coating covering the core, wherein the coating comprises the first material, and wherein the core of each of the first filaments is formed of a material having a lower conductivity than the first material; Provided are a plurality of second filaments comprising a second material having a second conductivity, wherein the first conductivity is greater than the second conductivity; and A web is formed, the web comprising a plurality of first filaments extending in a first direction and a plurality of second filaments extending in a second direction, wherein the first direction is perpendicular to the second direction; and At least two electrical terminals are provided for supplying power to the grid heating element, wherein the provision of at least two electrical terminals includes: Provide a first electrical terminal and a second electrical terminal; Each of the electrical terminals is connected to at least one of the first wires of the mesh, such that during use of the heater assembly, current is conducted between the first and second electrical terminals via the plurality of second wires.

12. The method of claim 11, further comprising heat-treating the mesh to bond the plurality of first filaments to the plurality of second filaments.

13. The method of claim 11 or 12, wherein the core comprises stainless steel.

14. The method of claim 11 or 12, wherein the coating has a thickness between 1 micrometer and 5 micrometers.

15. The method of claim 11 or 12, wherein the core of each filament in the first filament comprises the same material as each filament in the second filament.

16. The method of claim 11 or 12, wherein the first material comprises at least one of silver, gold, and platinum.

17. The method of claim 11 or 12, wherein the second material comprises stainless steel.

18. The method of claim 11 or 12, wherein forming the web comprises weaving the plurality of first filaments with the plurality of second filaments to form a woven web.

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