Heater assembly

Abstract

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

Description

Technical Field

[0001] This disclosure relates to a heater assembly. More particularly, this disclosure relates to a heater assembly for use in an aerosol generation system. This disclosure also relates to a method of assembling the heater assembly, a cylinder including the heater assembly, and an aerosol generation system including the heater assembly. Background Technology

[0002] In many known aerosol generation systems, a liquid aerosol-forming matrix is ​​heated and evaporated to form vapor. The vapor is then cooled and condensed to form an aerosol. In some aerosol generation systems, such as electrically heated smoking systems, this aerosol is then inhaled by the user.

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

[0004] When a liquid aerosol forming matrix of compounds with different boiling points is heated, the compound with the lower boiling point may evaporate before the compound with the higher boiling point. Alternatively or additionally, the compound with the lower boiling point may evaporate at a higher rate than the compound with the higher boiling point.

[0005] This may be undesirable because the interactions and combinations between different compounds can be limited. For example, a liquid aerosol forming matrix may include nicotine compounds and organic acid compounds with different boiling points. Both compounds can evaporate. Nicotine in the liquid aerosol forming matrix can form free nicotine base when it evaporates. However, it may be desirable to generate aerosols with nicotine salts rather than free nicotine bases. To form such nicotine salts, free nicotine bases can be protonated by evaporating organic acids. However, this protonation can be limited if the organic acids evaporate only after the nicotine has evaporated, or evaporate more slowly than required to protonate a suitable proportion of free nicotine bases.

[0006] Furthermore, the fact that some compounds in the aerosol-forming matrix evaporate faster than others may undesirably alter the properties of the generated aerosol over time (e.g., during the pumping process of the aerosol-generating system). This could be because, near the start of pumping, as the heating element is activated and the temperature rises, the liquid aerosol-forming matrix near the heating element can reach a first temperature at which the first compound with a lower boiling point evaporates, but the second compound with a higher boiling point does not. Then, in the later stages of pumping, the liquid aerosol-forming matrix near the heating element can reach a second temperature at which the second compound with a higher boiling point evaporates. However, by this time, most of the first compound in the liquid aerosol-forming matrix near the heating element may have already evaporated. Therefore, near the start of pumping, the generated aerosol may include a larger proportion of the first compound, and in the later stages of pumping, the generated aerosol may include a larger proportion of the second compound.

[0007] Alternatively or additionally, the properties of the generated aerosol can change during several pumping operations. This can occur if the compounds in the liquid aerosol forming matrix do not evaporate at an appropriate rate. For example, the liquid aerosol forming matrix may comprise X% by mass of a first compound and Y% by mass of a second compound. If the liquid aerosol forming matrix is ​​not evaporated to produce vapor comprising the first compound and the second compound in a mass ratio of X:Y, the composition of the liquid aerosol forming matrix can change during vapor generation. This can subsequently cause changes in the properties of the aerosol generated from the liquid aerosol forming matrix. Summary of the Invention

[0008] The purpose of this invention is to control the evaporation of various compounds that form a liquid aerosol matrix, wherein these compounds have different boiling points.

[0009] According to one aspect of this disclosure, a heater assembly is provided. The heater assembly is suitable for use in an aerosol generation system. The heater assembly may include a liquid aerosol forming matrix storage component. A heating element may include a first portion. A heating element may include a second portion. The first portion of the heating element may be embedded in the liquid aerosol forming matrix storage component. The second portion of the heating element may not be embedded in the liquid aerosol forming matrix storage component.

[0010] The heater assembly can provide regions of higher temperature and regions of lower temperature within the liquid aerosol forming matrix storage component. Alternatively or additionally, the heater assembly can provide regions within the liquid aerosol forming matrix storage component that increase in temperature at a greater rate and regions that increase in temperature at a lesser rate.

[0011] Advantageously, the heater assembly can improve the control of evaporation of different compounds in the liquid aerosol forming matrix. The heater assembly allows liquid aerosol forming matrix compounds with higher and lower boiling points to evaporate simultaneously at a desired rate. The heater assembly allows liquid aerosol forming matrix compounds with higher and lower boiling points to evaporate in a more preferred ratio. The heater assembly can provide the generation of aerosols with a more desired composition. The heater assembly can provide more consistent generation of aerosols with desired properties.

[0012] The heating element may include a third part and a fourth part. The third part of the heating element may be embedded in the liquid aerosol forming matrix storage component. The fourth part may not be embedded in the liquid aerosol forming matrix storage component.

[0013] Advantageously, this can create more regions of higher temperature and more regions of lower temperature within the liquid aerosol forming matrix storage component. Alternatively or additionally, this can provide more regions with temperatures increasing at a greater rate and more regions with temperatures increasing at a lesser rate within the liquid aerosol forming matrix storage component. This allows liquid aerosol forming matrix compounds with higher and lower boiling points to evaporate simultaneously at desired rates.

[0014] The second part of the heating element can extend between the first part and the third part. That is, the second part of the heating element can connect the first part of the heating element to the third part of the heating element. The third part can be connected to the first part only via the second part.

[0015] The third part of the heating element can extend between the second and fourth parts. That is, the third part of the heating element can connect the second part of the heating element to the fourth part of the heating element. The fourth part can be connected to the second part only via the third part.

[0016] The heating element (or one or more, or all, of the first, second, third, and fourth parts) may comprise a resistive material. The heater assembly may be configured such that, in use, current is passed through the one or more parts. This allows the one or more parts to be resistively heated. Thus, the one or more parts may be configured to be resistively heated.

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

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

[0019] The heating element (or one or more or all of the first, second, third, and fourth portions of the heating element) may comprise or be formed of any material having suitable electrical and mechanical properties (e.g., a suitable resistive material). Suitable materials include, but are not limited to: semiconductors (such as doped ceramics), “conductive” ceramics (such as molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made of ceramic and metallic materials. Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. 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; and nickel, iron, and cobalt-based superalloys; stainless steel; Iron-aluminum based alloys and iron-manganese-aluminum based alloys. This is a registered trademark of Titanium Metals Corporation, 1999 Broadway Suite 4300, Denver, Colorado. In composite materials, the resistive material may optionally be embedded in, encapsulated in, or coated with an insulating material, or vice versa, depending on the energy transfer kinetics and desired external physicochemical properties. The heating element may comprise a metal-etched foil insulating between two layers of inert material. In this case, the inert material may include… Polyimide or mica foil. It is a registered trademark of EIdu Pont de Nemours and Company, 1007 Market Street, Wilmington, Delaware 19898, United States of America.

[0020] The third and fourth parts can be configured to be heated by resistance. The third and fourth parts may include resistive material. The first and second parts can be configured to be heated by resistance. The first and second parts may include resistive material.

[0021] The heating element (or one or more, or all, of the first, second, third, and fourth portions) may include a sensor material. The heater assembly may be configured such that, in use, the one or more portions are inductively heated.

[0022] For example, the heater assembly can be configured for use in an aerosol generation system that includes a sensor (such as a sensor coil). The sensor can be located in an aerosol generation apparatus having a power supply. The aerosol generation apparatus can be configured to engage with the heater assembly or a cylinder including the heater assembly. Alternatively, the sensor can be located in a cylinder including the heater assembly. The cylinder can be configured to engage with an aerosol generation apparatus having a power supply.

[0023] The power supply device can be configured to pass alternating current through an inductor in the cylinder or an inductor in the aerosol generating device, so that the inductor generates a fluctuating electromagnetic field.

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

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

[0026] The sensor material can be, or can include, any material that can be inductively heated to a temperature sufficient to generate aerosols from the aerosol-forming matrix. Preferred sensor materials can be heated to temperatures exceeding 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. Preferred sensor materials can include metals or carbon, or both metals and carbon. Preferred sensor materials can include ferromagnetic materials, such as ferritic iron or ferromagnetic steel or stainless steel. Suitable sensor elements can be, or can include, one or more of graphite, molybdenum, silicon carbide, stainless steel, niobium, and aluminum. Preferred sensor materials can include 400 series stainless steel (e.g., grade 410, 420, or 430 stainless steel) or materials formed thereof. Different materials will dissipate different amounts of energy when positioned within an electromagnetic field with similar frequency and field strength values. Therefore, parameters of the sensor material, such as material type and size, can be varied to provide the desired power dissipation within a known electromagnetic field.

[0027] The third and fourth parts can be configured to be inductively heated. The third and fourth parts may include sensor material. The first and second parts can be configured to be inductively heated. The first and second parts may include sensor material.

[0028] Advantageously, in induction-heated aerosol generation systems, there is no need to form electrical contacts between the heater assembly and the aerosol generation device. Furthermore, the heating element does not require electrical connection to other components. This eliminates the need for welded parts or other bonding elements. A cylinder equipped with a heater assembly configured for induction heating allows for the production of simple, inexpensive, and robust cylinders. Cylinders are typically single-use products, produced in much larger quantities than the aerosol generation devices that operate with them. Therefore, reducing the cost of cylinders can result in significant cost savings for manufacturers. Additionally, induction heating provides improved energy conversion compared to resistance heating. This is because induction heating does not have the power losses associated with the resistance in the connection between the heating element and the power supply.

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

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

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

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

[0033] Advantageously, this can create regions of higher and lower temperatures. Alternatively or additionally, this can provide regions in the liquid aerosol forming matrix storage component that increase in temperature at a greater rate and regions that increase in temperature at a lesser rate. As explained above, this allows liquid aerosol forming matrix compounds with higher and lower boiling points to evaporate simultaneously at desired rates.

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

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

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

[0037] The heating element may bend into and out of the liquid aerosol forming matrix storage component. The heating element may include a strip of material that bends into and out of the liquid aerosol forming matrix storage component. The heating element or strip may bend into and out of the liquid aerosol forming matrix storage component along its length. Therefore, tracing along the length of the heating element or strip, the heating element or strip may alternately include portions embedded in the liquid aerosol forming matrix storage component, such as first and third portions, and portions not embedded in the liquid aerosol forming matrix storage component, such as second and fourth portions.

[0038] Advantageously, heater assemblies, including heating elements that zigzag into and out of the liquid aerosol-forming matrix storage component, can be manufactured relatively simply.

[0039] The heating element may include one or more of the following: a curved portion, an undulating portion, a folded portion, and a corrugated portion. A first portion of the heating element may include one or more of the following: a curved portion, an undulating portion, a folded portion, and a corrugated portion. A second portion of the heating element may include one or more of the following: a curved portion, an undulating portion, a folded portion, and a corrugated portion. A third portion of the heating element may include one or more of the following: a curved portion, an undulating portion, a folded portion, and a corrugated portion. A fourth portion of the heating element may include one or more of the following: a curved portion, an undulating portion, a folded portion, and a corrugated portion. A fifth portion of the heating element may include one or more of the following: a curved portion, an undulating portion, a folded portion, and a corrugated portion.

[0040] Advantageously, the bends, undulations, folds, and corrugations in the heating element allow for better control over the positions of higher and lower temperature regions. Alternatively or additionally, the bends, undulations, folds, and corrugations in the heating element allow for better control over the temperature difference between higher and lower temperature regions. For example, if a higher temperature is desired in a given area of ​​the liquid aerosol forming matrix storage component, the heating element may include undulations or corrugations in this area. This can increase the volume or surface area of ​​the heating element in this area, and thus increase the heat transferred from the heating element to this area.

[0041] The heating element may have a first end and a second end. The length of the heating element may extend from the first end to the second end. In the case where the heating element does not extend directly from the first end to the second end (i.e., extend in a straight line), the heating element may be considered to include one or more of the following: a curved portion, an undulating portion, a folded portion, and a corrugated portion.

[0042] A bend can refer to a gradual change in the orientation of the heating element, for example, a gradual change in the orientation of the heating element between the first end and the second end. Therefore, a bend can be formed in an arc or a "C" shape.

[0043] A fold can refer to a stepped change in the direction of the heating element, for example, a stepped change in the direction of the heating element between the first end and the second end. Therefore, the fold can form two sides of a polygon or a "V" shape.

[0044] The undulation can include multiple curves. For example, the undulation can refer to a gradual change in the orientation of the heating element in a first direction, followed by a gradual change in the orientation of the heating element in another direction (e.g., in the opposite direction). Therefore, the undulation can form a sine wave or an "S" shape.

[0045] The corrugated section may include multiple folds. For example, the corrugation may refer to a stepped change in the direction of the heating element, followed by another stepped change in the direction of the heating element. Therefore, the corrugation may form three sides of a rectangle, or an "M" shape, or an "N" shape.

[0046] Advantageously, heating elements comprising one or more of bends, undulations, folds, and corrugations can simplify the manufacture of heater assemblies having at least a portion of the heating element embedded in a liquid aerosol forming matrix storage component and at least a portion not embedded in the liquid aerosol forming matrix storage component. Furthermore, one or more of the bends, undulations, folds, and corrugations can allow the heating element to generate regions with higher temperatures. For example, a portion of the heating element embedded in the liquid aerosol forming matrix storage component can have a tightly bent "S" shape. The area of ​​the liquid aerosol forming matrix storage component surrounding this portion of the heating element can be heated to a higher temperature.

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

[0048] The amplitude of the undulations or corrugations can be measured in the direction perpendicular to the length of the heating element. The amplitude can also be measured in the direction of the thickness of the heating element. The amplitude can refer to half the height difference between the peak, or local maximum value, and the valley, or local minimum value of the undulations or corrugations.

[0049] The frequency of undulations or corrugations refers to the number of repetitions per unit distance (e.g., along the length of the heating element or between the first and second ends of the heating element). This type of frequency is often referred to as the spatial frequency. For example, in the case where the heating element comprises a regular sine wave, the wave is considered to be an undulation, and the frequency of these undulations is 1 divided by the wavelength of the wave.

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

[0051] The frequency of the undulating or corrugated part of the heating element can vary along the length of the heating element.

[0052] The amplitude of the undulations or corrugations of the heating element can vary along the length of the heating element.

[0053] Advantageously, changing the amplitude or frequency, or both amplitude and frequency, allows for better control over the location of higher and lower temperature regions. Alternatively or additionally, changing the amplitude or frequency, or both amplitude and frequency, allows for better control over the temperature difference between higher and lower temperature regions.

[0054] The heater assembly may include a reservoir for storing a liquid aerosol forming matrix.

[0055] Liquid aerosol forming matrix storage components can store or be configured to store liquid aerosol forming matrix.

[0056] The liquid aerosol forming matrix (LAM) storage component can be in fluid communication with the reservoir. In this case, during use, sections of the heating element farther from the LAM reservoir, or areas of the LAM storage component surrounding the heating element, can reach higher temperatures compared to sections or areas closer to the LAM reservoir. This is because for sections of the heating element closer to the LAM reservoir, more heat can be transferred from the heating element to the LAM reservoir, or heat can be transferred from the heating element to the LAM reservoir more quickly.

[0057] Advantageously, the liquid aerosol forming matrix storage component, which is in fluid communication with the reservoir, allows for rapid and automatic replenishment of the liquid aerosol forming matrix that has evaporated and been removed from the liquid aerosol forming matrix storage component.

[0058] A liquid aerosol forming matrix (LAM) storage component may include, or may be, a material impregnated with, or configured to be impregnated with, a liquid aerosol forming matrix. The LAM storage component may have a fibrous or sponge-like structure. The LAM storage component may include capillary materials. The LAM storage component may include capillary bundles. For example, the LAM storage component may include one or more of fibers, wires, and fine-pore tubes.

[0059] Liquid aerosol forming matrix storage components may include sponge-like or foam-like materials. The structure of the liquid aerosol forming matrix storage component may form multiple pores or tubes, through which liquid can be transported via capillary action.

[0060] Liquid aerosol forming matrix storage components can include any suitable material or combination of materials. Suitable materials include, but are not limited to: sponge or foam materials, ceramic-based or graphite-based materials in the form of fibers or sintered powders, foamed metals or plastic materials, such as fibrous materials made from spun or extruded fibers, such as cellulose acetate, polyester or bonded polyolefins, polyethylene, polyester or polypropylene fibers, nylon fibers, or ceramics. Liquid aerosol forming matrix storage components can include ceramic materials. Liquid aerosol forming matrix storage components can have any suitable capillary action and porosity for use with different liquid aerosol forming matrices with different physical properties.

[0061] The heating element may include a fifth portion located within a reservoir. Unless otherwise explicitly stated, the term "reservoir" may refer to a reservoir for storing a liquid aerosol forming matrix or a reservoir of liquid aerosol forming matrix. Unless otherwise explicitly stated, the term "reservoir" may refer to a reservoir for storing a free-flowing liquid aerosol forming matrix or a reservoir of a free-flowing liquid aerosol forming matrix.

[0062] The reservoir may be configured to store, or be able to store, at least 0.2, 0.5, or 1 ml of liquid aerosol forming matrix. The reservoir may be configured to store, or be able to store less than 2, 1.8, or 1.5 ml of liquid aerosol forming matrix.

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

[0064] Advantageously, a mesh heating element, or a heating element comprising a mesh, can provide a large surface area in contact with the liquid aerosol forming matrix. This large surface area can provide for efficient evaporation of the liquid aerosol forming matrix.

[0065] The heater assembly may include a second heating element. Features described with respect to the first heating element may be applied to the second heating element. Similarly, features described with respect to portions of the first heating element may be applied to corresponding portions or portions of the second heating element. For example, one or more of the material and shape of the first heating element may be applied to the second heating element. Alternatively, the second heating element may have a different shape or form than the heating element.

[0066] Advantageously, the second heating element can increase the evaporation rate of the liquid aerosol forming matrix in the liquid aerosol forming matrix storage component. Additionally, the distance between the first and second heating elements can be selected to affect the temperature of a region of the liquid aerosol forming matrix storage component during use. For example, a region of the liquid aerosol forming matrix storage component where the first and second heating elements are closer together can achieve a higher temperature compared to a region where the first and second heating elements are further spaced apart.

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

[0068] Part Two can extend between Part One and Part Three. Part Three can extend between Part Two and Part Four.

[0069] The first portion of the second heating element may be embedded in the liquid aerosol forming matrix storage component. The second portion of the second heating element may not be embedded in the liquid aerosol forming matrix storage component. The third portion of the second heating element may be embedded in the liquid aerosol forming matrix storage component. The fourth portion of the second heating element may not be embedded in the liquid aerosol forming matrix storage component. The fifth portion of the second heating element may be located in the storage container.

[0070] This can advantageously create more relatively high-temperature areas and more relatively low-temperature areas in the liquid aerosol forming matrix storage component.

[0071] The second heating element can bend into and out of the liquid aerosol-forming matrix storage component.

[0072] The second heating element may include one or more of the following: a curved portion, an undulating portion, a folded portion, and a corrugated portion.

[0073] The second heating element may be spaced apart from the first heating element in a direction transverse to the length of the first heating element. The second heating element may be spaced apart from the first heating element in a direction transverse to the width of the first heating element. The second heating element may be positioned adjacent to the first heating element.

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

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

[0076] The first heating element can be configured to be induction heated.

[0077] The first heating element and the second heating element can operate independently. The first heating element can be heated by resistance or induction without substantially increasing the temperature of the second heating element. The temperature of the first heating element can be raised while the temperature of the second heating element remains substantially constant. The first and second heating elements can be connected to different power sources.

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

[0079] The third or fourth part, or both of the third and fourth parts, of the heating element can be configured to be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. In use, the third or fourth part, or both of the third and fourth parts, of the heating element can be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius.

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

[0081] The liquid aerosol forming matrix storage component can be configured to store, or can store at least 0.02, 0.05, 0.1, 0.2, or 0.5 ml of liquid aerosol forming matrix.

[0082] According to another aspect of this disclosure, a method for assembling a heater assembly is provided. The heater assembly may be a heater assembly according to this disclosure. The method may include providing a liquid aerosol forming matrix storage component. The method may include providing a heating element comprising a first portion and a second portion. The method may include embedding the first portion of the heating element into the liquid aerosol forming matrix storage component.

[0083] When the heating element includes a third portion, the method may include embedding the third portion of the heating element into a liquid aerosol forming matrix storage component.

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

[0085] The cylinder can be configured to engage with and disengage from an aerosol generating device. The aerosol generating device may include a power source. The power source can be configured to supply power to a heating element. The power source can also be configured to supply power to the heating element only when the cylinder is engaged with the aerosol generating device.

[0086] The cylinder may include an air inlet. The cylinder may include an air outlet. The air inlet may be in fluid communication with the air outlet. A heating element may be located downstream of the air inlet. A heating element may be located upstream of the air outlet. In use, this allows air to flow in through the air inlet, then across, over, through, or through the heater assembly or heating element, and then through the air outlet.

[0087] The cartridge may include a mouthpiece. The mouthpiece may include an air outlet. In use, when the cartridge is engaged with an aerosol generating device, the user can inhale through the mouthpiece of the cartridge. This allows air to flow in through the air inlet, then across, over, through, or through the heater assembly or heating element, and then through the air outlet.

[0088] Advantageously, providing an airflow that crosses, passes over, goes through, or passes through the heater assembly or heating element allows vapor formed by the heater assembly to be entrained in the airflow.

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

[0090] The electrical contacts can be configured to form an electrical connection with the corresponding electrical contacts on the aerosol generating device when the cylinder is engaged with the aerosol generating device.

[0091] The second part, or the fourth part, or both the second and fourth parts of the heating element, can be located in the airflow path between the air inlet and the air outlet of the cylinder.

[0092] Advantageously, this can increase the temperature of the airflow during use. Some users may prefer this, as it more accurately simulates the experience of smoking a regular cigarette or cigar.

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

[0094] The aerosol generation system may include a cylinder according to the present disclosure.

[0095] The system may include an aerosol generating device. The system may include a cylinder comprising a heater assembly.

[0096] The cylinder can be configured to engage with the aerosol generating device. The cylinder can also be configured to detach from the aerosol generating device.

[0097] An aerosol generation system (e.g., an aerosol generation device of an aerosol generation system) may include a power supply device, such as a battery. The power supply device may be configured to supply power to a heating element. This can be used to heat the heating element. The power supply device may be configured to supply power to the heating element only when the cylinder is engaged with the aerosol generation device.

[0098] The aerosol generating apparatus may include a controller. The controller may be configured to control the power supply from the power supply device. Therefore, the controller can control the heating of the heating element.

[0099] The power supply device can be configured to supply power to the heating element for resistance heating. The power supply device can also be configured to supply power to the heating element for induction heating.

[0100] The aerosol generating device can be configured to engage with and disengage from a cylinder via a snap-fit ​​connection, corresponding thread, or any other suitable means. The aerosol generating device can be configured as at least a portion of the receiving cylinder. For example, the aerosol generating device may include a chamber configured as at least a portion of the receiving cylinder.

[0101] The aerosol generating device may include an air inlet. The aerosol generating device may include an air outlet. When the aerosol generating device is connected to the cylinder, the air outlet of the aerosol generating device may be in fluid communication with the air inlet of the cylinder.

[0102] The power supply device can be electrically connected to the first and second electrical contacts of the aerosol generating device. These first and second electrical contacts can be configured to form an electrical connection with corresponding first and second electrical contacts on the cylinder when the cylinder is engaged with the aerosol generating device. These corresponding first and second electrical contacts on the cylinder can be electrically connected to the heating element. Therefore, the power supply device can be configured to supply power to the heating element by allowing current to flow through it.

[0103] The cylinder or aerosol generating device may include a sensor, such as an induction coil. The heating element may be or may include a sensor material.

[0104] The power supply can be configured to pass current (such as high-frequency alternating current) through the inductor, causing the inductor to generate a fluctuating electromagnetic field. This, in turn, generates eddy currents and hysteresis losses in the inductor material. This can cause the inductor material to heat up. Therefore, the power supply using the inductor can be configured to inductively heat the heating element.

[0105] Suitable sensor materials include those previously mentioned in the heater assembly according to this disclosure.

[0106] The inductor can be an induction coil. The inductor can be located within a cylinder that includes the heater assembly. The inductor can be positioned around or around a portion of the heating element. For example, the inductor can be an induction coil and can be spirally positioned around or around a portion of the heating element.

[0107] The sensors can be electrically connected to electrical contacts on the cylinder. When the cylinder is engaged with the aerosol generating device, these electrical contacts can be electrically connected to corresponding electrical contacts on the aerosol generating device, which in turn are electrically connected to a power supply device within the aerosol generating device. When the cylinder is engaged with the aerosol generating device, the power supply device of the aerosol generating device can be configured to pass current through the sensors to generate a fluctuating electromagnetic field, thereby heating the sensor material of the heating element.

[0108] A sensor (such as an induction coil) may be located within the aerosol generating apparatus. The sensor may be electrically connected to a power supply for the aerosol generating apparatus. The aerosol generating apparatus may be configured to engage with a heater assembly or a cylinder including the heater assembly. For example, the aerosol generating apparatus may include a chamber for receiving at least a portion of the heater assembly or at least a portion of the cylinder including the heater assembly. The induction coil may be disposed around at least a portion of this chamber. For example, the induction coil may be helical around at least a portion of the chamber. Thus, when the heater assembly or the cylinder including the heater assembly is engaged with the aerosol generating apparatus, the induction coil may be disposed or helical around a heating element or a portion of the heating element. When at least a portion of the heater assembly or at least a portion of the cylinder including the heater assembly is received in the chamber of the aerosol generating apparatus, the power supply for the aerosol generating apparatus may be configured to pass current through the sensor to generate a fluctuating electromagnetic field, thereby heating the sensor material of the heating element.

[0109] As mentioned above, induction heating advantageously allows for the production of simple, inexpensive, and robust cylinders. Furthermore, compared to resistance heating, induction heating offers improved energy conversion.

[0110] Aerosol generation systems can be smoking systems, such as electrically operated smoking systems. Aerosol generation systems can also be used for recreational purposes. In use, aerosol generation systems can be adapted to deliver nicotine to users or configured to deliver nicotine to users.

[0111] Aerosol generation systems can be portable. Aerosol generation systems can have a size comparable to a conventional cigar or cigarette. Smoking systems can have an overall length between 30 mm and 200 mm. Smoking systems can have an outer diameter between 5 mm and 30 mm. 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.

[0112] As used herein, the term "aerosol-forming matrix" refers to a matrix capable of releasing volatile compounds that can form aerosols. These volatile compounds can be released by heating or burning the aerosol-forming matrix.

[0113] The aerosol forming matrix can include a variety of compounds. These compounds can have different boiling points. For example, the aerosol forming matrix can include a first compound having a first boiling point at atmospheric pressure, and a second compound having a second boiling point at atmospheric pressure, wherein the first boiling point is greater than the second boiling point.

[0114] Aerosol forming matrices may include aerosol forming agents. As used herein, the term "aerosol forming agent" refers to any suitable compound or mixture of compounds that promotes the formation of aerosols during use, such as stable aerosols that are substantially resistant to thermal degradation at the system's operating temperature. 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 acid esters; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate.

[0115] The aerosol-forming matrix may include nicotine. The aerosol-forming matrix may include water. The aerosol-forming matrix may include glycerol, also known as glycerol, which has a higher boiling point than nicotine. The aerosol-forming matrix may include propylene glycol. The aerosol-forming matrix may include plant-based materials. The aerosol-forming matrix may include homogenized plant-based materials. The aerosol-forming matrix may include tobacco. The aerosol-forming matrix may include tobacco-containing materials. Tobacco-containing materials may contain volatile tobacco flavor compounds. These compounds can be released from the aerosol-forming matrix upon heating. The aerosol-forming matrix may include homogenized tobacco materials. The aerosol-forming matrix may include other additives and ingredients, such as flavorings.

[0116] As used herein, the term "liquid aerosol forming matrix" refers to an aerosol forming matrix in a concentrated form. Therefore, a "liquid aerosol forming matrix" can be or may include one or more of a liquid, a gel, or a paste. If the liquid aerosol forming matrix is ​​or includes a gel or paste, the gel or paste can be liquefied upon heating. For example, a gel or paste can be liquefied when heated to temperatures below 50, 75, 100, 150, or 200 degrees Celsius.

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

[0118] As used herein, the term "embedded" can be used to mean enclosing, enclosing, closing, surrounding, or circling. Additionally, in the case where a first component is "embedded" in a second component, this can mean that the first component is in contact with the second component. For example, when a portion of a heating element is described as being embedded in a component, this can mean that this portion of the heating element is surrounded by and in contact with the component.

[0119] 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.

[0120] Example Ex1: A heater assembly for an aerosol generation system, the heater assembly comprising:

[0121] Liquid aerosol forming matrix storage component; and

[0122] The heating element comprises a first part and a second part.

[0123] The first portion of the heating element is embedded in the liquid aerosol forming matrix storage component, and the second portion of the heating element is not embedded in the liquid aerosol forming matrix storage component.

[0124] Example Ex2: The heater assembly according to Example Ex1, wherein the heating element includes a third part and a fourth part, wherein the third part of the heating element is embedded in the liquid aerosol forming matrix storage component, and the fourth part is not embedded in the liquid aerosol forming matrix storage component.

[0125] Example Ex3: A heater assembly according to Example Ex2, wherein the second portion of the heating element extends between the first portion and the third portion.

[0126] Example Ex4: A heater assembly according to Example Ex2 or Example Ex3, wherein the third portion of the heating element extends between the second portion and the fourth portion.

[0127] Example Ex5: A heater assembly according to any one of Examples Ex2 to Ex4, wherein the third and fourth portions are configured to be heated by resistance.

[0128] Example Ex6: A heater assembly according to any one of Examples Ex2 to Ex5, wherein the third and fourth portions comprise resistive material.

[0129] Example Ex7: A heater assembly according to any of the preceding examples, wherein the first portion and the second portion are configured to be heated by resistance.

[0130] Example Ex8: A heater assembly according to any of the preceding examples, wherein the first part and the second part comprise resistive material.

[0131] Example Ex9: A heater assembly according to any one of Examples Ex2 to Ex4, wherein the third and fourth portions are configured to be induction heated.

[0132] Example Ex10: A heater assembly according to any one of Examples Ex2 to Ex4, or Ex9, wherein the third and fourth portions include sensor material.

[0133] Example Ex11: A heater assembly according to any one of Examples Ex1 to Ex4, Ex9, or Ex10, wherein the first portion and the second portion are configured to be induction heated.

[0134] Example Ex12: A heater assembly according to any one of Examples Ex1 to Ex4, Ex9, Ex10, or Ex11, wherein the first part and the second part include sensor material.

[0135] Example Ex13: A heater assembly according to any of the preceding examples, wherein the heating element comprises a strip of material.

[0136] Example Ex14: A heater assembly according to any of the preceding examples, wherein the cross-section of the heating element varies along the length of the heating element.

[0137] Example Ex15: A heater assembly according to any of the preceding examples, wherein the minimum cross-sectional area along the length of the heating element is at least 10% smaller than the maximum cross-sectional area along the length of the heating element.

[0138] Example Ex16: A heater assembly according to any of the preceding examples, wherein the width or thickness of the heating element, or both the width and thickness, varies along the length of the heating element.

[0139] Example Ex17: A heater assembly according to any of the preceding examples, wherein the heating element deflects into and out of the liquid aerosol forming matrix storage component.

[0140] Example Ex18: A heater assembly according to any of the preceding examples, wherein the heating element includes one or more of a curved portion, an undulating portion, a folded portion, and a corrugated portion.

[0141] Example Ex19: A heater assembly according to any of the preceding examples, wherein the heating element includes one or more irregular undulations and irregular corrugations along the length of the heating element.

[0142] Example Ex20: A heater assembly according to any of the foregoing examples, wherein the frequency of the undulations or corrugations of the heating element varies along the length of the heating element.

[0143] Example Ex21: A heater assembly according to any of the preceding examples, wherein the amplitude of the undulations or corrugations of the heating element varies along the length of the heating element.

[0144] Example Ex22: A heater assembly according to any of the foregoing examples includes a reservoir for storing a liquid aerosol forming matrix.

[0145] Example Ex23: The heater assembly according to Ex22, wherein the reservoir is in fluid communication with the liquid aerosol forming matrix storage component.

[0146] Example Ex24: A heater assembly according to Ex22 or Ex23, wherein the heating element includes a fifth part located in the reservoir.

[0147] Example Ex25: A heater assembly according to Ex22, Ex23 or Ex24, wherein the reservoir includes at least 1 ml of liquid aerosol forming matrix.

[0148] Example Ex26: A heater assembly according to any of the preceding examples includes a second heating element.

[0149] Example Ex27: The heater assembly according to Ex26, wherein the second heating element deflects into and out of the liquid aerosol forming matrix storage component.

[0150] Example Ex28: A heater assembly according to Ex26 or Ex27, wherein the second heating element includes one or more of a curved portion, an undulating portion, a folded portion, and a corrugated portion.

[0151] Example Ex29: A heater assembly according to any one of Examples Ex26 to Ex28, wherein the second heating element is spaced apart from the heating element in a direction transverse to the length of the heating element.

[0152] Example Ex30: A heater assembly according to any one of Examples Ex26 to Ex29, wherein the second heating element is a mesh heating element.

[0153] Example Ex31: A heater assembly according to any of the foregoing examples, wherein, in use, both the first part and the second part are heated to at least 50 degrees Celsius.

[0154] Example Ex32: A heater assembly according to any of the preceding examples, wherein the heating element is a mesh heating element.

[0155] Example Ex33: A heater assembly according to any of the foregoing examples, wherein the liquid aerosol forming matrix storage component includes a capillary retaining material.

[0156] Example Ex34: In a heater assembly according to any of the preceding examples, the liquid aerosol forming matrix storage component is configured to store at least 0.05 ml of liquid aerosol forming matrix.

[0157] Example Ex35: A heater assembly according to any of the preceding examples, wherein at least 0.05 ml of liquid aerosol forming matrix is ​​stored in the liquid aerosol forming matrix storage component.

[0158] Example Ex36: A cylinder comprising a heater assembly according to any of the preceding examples.

[0159] Example Ex37: A method for assembling a heater assembly according to any one of Examples EX1 to EX35, the method comprising:

[0160] Provides storage components for liquid aerosol formation matrix;

[0161] A heating element is provided, the heating element comprising a first part and a second part; and

[0162] The first portion of the heating element is embedded in the liquid aerosol forming matrix storage component.

[0163] Example Ex38: An aerosol generation system comprising a heater assembly according to any one of Examples Ex1 to Ex35.

[0164] Example Ex39: An aerosol generation system according to EX38, the aerosol generation system comprising an aerosol generation device and a cylinder including the heater assembly.

[0165] Example Ex40: An aerosol generating system according to EX39, wherein the cylinder is configured to engage with and disengage from the aerosol generating device.

[0166] Example Ex41: An aerosol generating system according to any one of Examples Ex38, Ex39, or Ex40, wherein the aerosol generating system includes a power supply device configured to supply power to the heating element to heat the heating element.

[0167] Example Ex42: An aerosol generating system according to EX39 or EX40, wherein the aerosol generating device includes a power supply device configured to supply power to the heating element to heat the heating element.

[0168] Example Ex43: An aerosol generation system according to Ex41 or Ex42, wherein the power supply device is configured to supply power to the heating element to resistively heat the heating element.

[0169] Example Ex44: An aerosol generation system according to Ex41 or Ex42, wherein the power supply device is configured to supply power to the heating element to inductively heat the heating element.

[0170] Example Ex45: An aerosol generating system according to any one of Examples Ex38 to Ex44, wherein the aerosol generating system has a total length between 30 mm and 200 mm.

[0171] Example Ex46: An aerosol generating system according to any one of Examples Ex38 to Ex45, wherein the aerosol generating system has an outer diameter between 5 mm and 30 mm.

[0172] Example Ex47: An aerosol generating system according to any one of Examples Ex38 to Ex46, wherein the aerosol generating system is portable.

[0173] Example Ex48: An aerosol generating system according to any one of Examples Ex38 to Ex47, wherein the aerosol generating system is a smoking system. Attached Figure Description

[0174] Several examples will now be described further with reference to the accompanying drawings, in which:

[0175] Figure 1 A schematic cross-sectional view of a first aerosol generation system is shown, the first aerosol generation system including a cylinder equipped with a first heater assembly;

[0176] Figure 2 A schematic cross-sectional view of the first heater assembly is shown;

[0177] Figure 3 A schematic perspective view of the first heater assembly is shown;

[0178] Figure 4 A schematic cross-sectional view of a second aerosol generation system is shown, the second aerosol generation system including a cylinder equipped with a second heater assembly;

[0179] Figure 5 A schematic cross-sectional view of the second heater assembly is shown; and

[0180] Figure 6 A schematic perspective view of the second heater assembly is shown. Detailed Implementation

[0181] Figure 1A schematic cross-sectional view of a first aerosol generation system 100 is shown. The aerosol generation system 100 includes an aerosol generation device 150 and a cylinder 200. In this example, the aerosol generation system 100 is an electrically operated smoking system.

[0182] The aerosol generating device 150 is portable and has a size equivalent to a conventional cigar or cigarette. Device 150 includes a battery 152 (such as a lithium iron phosphate battery) and a controller 154 electrically connected to the battery 152. Device 150 also includes two electrical contacts 156, 158 electrically connected to the battery 152. This electrical connection is a wired connection and... Figure 1 Not shown in the image.

[0183] The cylinder 200 includes a first electrical contact 214 and a second electrical contact 216, an air inlet 202, an air outlet 204, and a first heater assembly 300. The air inlet 202 is in fluid communication with the air outlet 204. The heater assembly 300 is positioned downstream of the air inlet 202 and upstream of the air outlet 204. The heater assembly 300 includes a liquid aerosol forming matrix storage component 302 in fluid communication with a reservoir 303 of the liquid aerosol forming matrix. The heater assembly 300 also includes a heating element 304. The first electrical contact 214 and the second electrical contact 216 are electrically connected to the heating element 304.

[0184] In this system 100, the liquid aerosol forming matrix comprises approximately 74 wt% glycerol, 24 wt% propylene glycol, and 2 wt% nicotine, but any suitable matrix can be used. Nicotine has a boiling point of approximately 247°C at atmospheric pressure, glycerol has a boiling point of approximately 290°C, and propylene glycol has a boiling point of approximately 188°C. Therefore, when this liquid aerosol forming matrix is ​​initially heated to form an aerosol, some systems may undesirably cause a disproportionately large amount of propylene glycol (which has the lowest boiling point of the matrix-forming compounds) to evaporate. This could result in the delivery of less desirable aerosols to the user, such as aerosols comprising a smaller proportion of nicotine than desired. This could also undesirably alter the relative proportions of the compounds in the matrix over longer periods. The present invention can eliminate or at least reduce these undesirable effects.

[0185] The heating element 304 is a strip of material. In this example, the material is stainless steel, but any suitable material can be used. The heating element 304 includes a first portion 306, a second portion 308, a third portion 310, and a fourth portion 312. The second portion 308 extends between the first portion 306 and the third portion 310. The third portion 310 extends between the second portion 308 and the fourth portion 312. The first portion 306 and the third portion 310 are embedded in the liquid aerosol forming matrix storage component 302. The second portion 308 and the fourth portion 312 are not embedded in the liquid aerosol forming matrix storage component 302. Figure 1 In the example shown, the second part 308 and the fourth part 312 are located in the airflow path between the air inlet 202 and the air outlet 204 of the cylinder 200.

[0186] exist Figure 1 In this embodiment, the aerosol generating device 150 is engaged with the cylinder 200. In this example, the cylinder 200 is engaged with the aerosol generating device 150 via the thread 206 of the cylinder 200, which mates with the corresponding thread 162 of the aerosol generating device 150.

[0187] In this example, the liquid aerosol forming matrix storage component 302 is a capillary material with a fibrous structure. Figure 1 In the example shown, the capillary material is made of polyester, but any suitable material can be used.

[0188] In use, the user inhales through the air outlet 204 of the cylinder 200. Simultaneously, the user presses a button (not shown) on the aerosol generating device 150. Pressing this button sends a signal to the controller 154, which supplies power from the battery 152 to the heating element 304 via the electrical contacts 156, 158 of the aerosol generating device and the electrical contacts 214, 216 of the cylinder. This causes current to flow through the heating element 304, thereby resistively heating the heating element 304. In other instances, an airflow sensor or pressure sensor is located in the cylinder 200 and electrically connected to the controller 154. The airflow sensor or pressure sensor detects that the user is inhaling through the air outlet 204 of the cylinder 200 and sends a signal to the controller 154 to supply power to the heating element 304. In these instances, the user therefore does not need to press a button to heat the heating element 304.

[0189] As the heating element 304 is heated, regions with relatively high temperatures and relatively low temperatures are generated in the liquid aerosol forming matrix storage component 302. Relatively low-temperature regions can be generated in areas where the heating element 304 is closer to the liquid aerosol forming matrix in the storage unit 303. This is because heat from the heating element 304 dissipates into the storage unit 303 more quickly in these areas. Relatively low-temperature regions can also be generated in areas farther from the heating element. Regions with relatively high temperatures can be generated due to the shape of the heating element. For example, the heating element can be shaped such that the volume or surface area of ​​the heating element in a given volume at a first location in the liquid aerosol forming matrix storage component is greater than the volume or surface area of ​​the heating element in the same given volume at a second location in the liquid aerosol forming matrix storage component. In this case, the average temperature of the liquid aerosol forming matrix in the first location can be greater than the average temperature of the liquid aerosol forming matrix in the second location.

[0190] The creation of higher and lower temperature regions causes the compounds of the liquid aerosol forming matrix with higher and lower boiling points in the liquid aerosol forming matrix storage component 302 to evaporate simultaneously. The creation of these higher and lower temperature regions also causes the compounds of the liquid aerosol forming matrix with higher and lower boiling points in the liquid aerosol forming matrix storage component 302 to evaporate at a desired rate.

[0191] When a user inhales through the air outlet 204 of the cylinder 200, air is drawn into the air inlet 202. This air then crosses the heater assembly 300 and travels toward the air outlet 204. This airflow carries vapor formed from the liquid aerosol forming matrix in the liquid aerosol forming matrix storage component 302, heated by the heating element 304. Due to the generation of higher and lower temperature regions, as explained above, the vapor comprises different compounds with different boiling points in desired proportions. This carried vapor is then cooled and condensed to form an aerosol. This aerosol is then delivered to the user via the air outlet 204. As the liquid aerosol forming matrix in the liquid aerosol forming matrix storage component 302 is heated, evaporated, and entrained in the airflow, liquid aerosol forming matrix from the reservoir 303 travels into the liquid aerosol forming matrix storage component 302. This liquid aerosol forming matrix from the reservoir 303 effectively replaces the evaporated liquid aerosol forming matrix. The liquid aerosol forming matrix from the reservoir 303 can be at least partially drawn into the liquid aerosol forming matrix storage component 302 via capillary action. This is because the liquid aerosol forming matrix storage component 302 is a capillary material with a fibrous structure.

[0192] Figure 2A schematic cross-sectional view of the first heater assembly 300 is shown. The width of the heating element 304 (its width in...) Figure 2 The direction in which the page is entered can change, but in Figure 2 In the examples shown, it is constant. However, as... Figure 2 As shown, the thickness of the heating element 304 is not constant. Instead, the thickness gradually decreases from the second portion 308 to the third portion 310, and then gradually increases from the third portion 310 to the fourth portion 312. The minimum thickness of the heating element 304 is in the third portion 310 embedded in the liquid aerosol forming matrix storage component 302. This minimum thickness of the heating element 304 is approximately 50% of the maximum thickness of the heating element in the first portion 306. Therefore, the resistance of the third portion 310 is greater than that of the other portions, and in use, the third portion 310 will be resistively heated to a higher temperature than the other portions. This can advantageously increase the temperature of the liquid aerosol forming matrix near the third portion 310 of the heating element 304.

[0193] Figure 3 A schematic perspective view of the first heater assembly 300 is shown. Figure 3 As shown, the heating element 304 includes a bent portion that bends into and out of the liquid aerosol forming matrix storage member 302. The end of the heating element 304 extends beyond the liquid aerosol forming matrix storage member 302 to facilitate easy electrical connection to the electrical contacts of the cylinder 200. Figure 3 (Not shown in the image).

[0194] Figure 4 A schematic cross-sectional view of a second aerosol generation system 400 is shown. The aerosol generation system 400 includes an aerosol generation device 450 and a cylinder 500 equipped with a second heater assembly 600. In this example, the aerosol generation system 400 is an electrically operated fumigation system.

[0195] The aerosol generating device 450 is portable and has a size equivalent to that of a conventional cigar or cigarette. Device 450 includes a battery 452 (such as a lithium iron phosphate battery) and a controller 454 electrically connected to the battery 452. Device 450 also includes an induction coil 456 electrically connected to the battery 452. Device 450 also includes an air inlet 458 and an air outlet 460 in fluid communication with the air inlet 458.

[0196] Cylinder 500 includes an air inlet 502, an air outlet 504, and a second heater assembly 600. The air inlet 502 and air outlet 504 are in fluid communication. The heater assembly 600 is positioned downstream of the air inlet 502 and upstream of the air outlet 504. When cylinder 500 is engaged with aerosol generating device 450, as... Figure 4As shown, the air outlet 460 of the device 450 is adjacent to the air inlet 502 of the cylinder 500. Therefore, in use, when a user draws air through the air outlet 504 of the cylinder 500, the airflow passes through the air inlet 458 of the device 450, then through the air outlet 460 of the device 450, then through the air inlet 502 of the cylinder 500, then through the heater assembly 600, and then through the air outlet 504 of the cylinder 500.

[0197] exist Figure 4 In this embodiment, the cylinder 500 is engaged with the aerosol generating device 450. In this example, the cylinder 500 is engaged with the aerosol generating device 450 via orifices 506 and 508, which are connected to the corresponding protrusions 462 and 464 on the aerosol generating device 450 via a snap-fit ​​connection.

[0198] The heater assembly 600 includes a first heating element 604 and a second heating element (in Figure 4 The storage unit 603 (not visible in the image) contains a liquid aerosol forming matrix, and the liquid aerosol forming matrix storage component 602 is in fluid communication with the storage unit 603. The second heating element 605 is located in... Figure 4 It is invisible in the middle, but in Figure 6 It is visible in the middle.

[0199] In this system 400, the liquid aerosol forming matrix comprises approximately 98% by weight glycerol and 2% by weight nicotine, but any suitable matrix can be used. Nicotine has a boiling point of approximately 247 degrees Celsius at atmospheric pressure, and glycerol has a boiling point of approximately 290 degrees Celsius. Therefore, when this liquid aerosol forming matrix is ​​initially heated to form an aerosol, some systems may undesirably cause a disproportionately large amount of nicotine (which has the lowest boiling point of the matrix-forming compounds) to evaporate. This could result in an undesirable aerosol being delivered to the user. It could also undesirably alter the relative proportions of the compounds in the matrix over a longer period. The present invention can eliminate or at least reduce these undesirable effects.

[0200] The first heating element 604 includes a strip of sensor material. In this example, the sensor material is aluminum, but any suitable sensor material can be used. The first heating element 604 includes multiple portions embedded in the liquid aerosol forming matrix storage component 602, and multiple portions not embedded in the liquid aerosol forming matrix storage component 602. Two of the portions not embedded in the liquid aerosol forming matrix storage component 602 are located in a reservoir 603.

[0201] exist Figure 4In the example shown, the second heating element 605 is the same as the first heating element 604, but two (or more) different heating elements can be used. The second heating element 605 is positioned adjacent to the first heating element 604.

[0202] In this example, the liquid aerosol forming matrix storage component 602 is a capillary material with a fibrous structure. The capillary material is formed of polyester, but any suitable material can be used.

[0203] In use, the user inhales through the air outlet 504 of the cylinder 500. Simultaneously, the user presses a button (not shown) on the aerosol generating device 450. Pressing this button sends a signal to the controller 454, causing the battery 452 to supply a high-frequency current to the induction coil 456. This causes the induction coil 456 to generate a fluctuating electromagnetic field. The first heating element 604 and the second heating element 605 are positioned within this fluctuating electromagnetic field. Therefore, this fluctuating electromagnetic field generates eddy currents and hysteresis losses in the first heating element 604 and the second heating element 605. Consequently, the first heating element 604 and the second heating element 605 are inductively heated. In other embodiments, an airflow sensor or pressure sensor is located in the device 450 and electrically connected to the controller 454. The airflow sensor or pressure sensor detects that the user is inhaling through the air outlet 504 of the cylinder 500 and sends a signal to the controller 454 to supply a high-frequency current to the induction coil 456, thereby heating the first heating element 604 and the second heating element 605. In these examples, the user therefore does not need to press a button to heat the first heating element 604 and the second heating element 605.

[0204] When the first heating element 604 and the second heating element 605 are heated, regions with relatively high temperatures and regions with relatively low temperatures are generated in the liquid aerosol forming matrix storage component 602. Lower temperature regions can be generated in areas where the heating element 604 is closer to the storage container 603 of the liquid aerosol forming matrix. This is because heat from the heating element 604 in these regions is dissipated into the storage container 603 more quickly. Relatively low temperature regions can be generated in areas farther from the heating element. Regions with relatively high temperatures can be generated due to the shape of the heating element. For example, the heating element can be shaped such that the volume or surface area of ​​the heating element in a given volume at a first location in the liquid aerosol forming matrix storage component is greater than the volume or surface area of ​​the heating element in the same given volume at a second location in the liquid aerosol forming matrix storage component. In this case, the average temperature of the liquid aerosol forming matrix at the first location can be greater than the average temperature of the liquid aerosol forming matrix at the second location.

[0205] The creation of higher and lower temperature regions causes the compounds of the liquid aerosol forming matrix with higher and lower boiling points in the liquid aerosol forming matrix storage component 602 to evaporate simultaneously. The creation of higher and lower temperature regions also causes the compounds of the liquid aerosol forming matrix with higher and lower boiling points in the liquid aerosol forming matrix storage component 302 to evaporate at a desired rate.

[0206] When a user inhales through the air outlet 504 of the cylinder 500, air is drawn into the air inlet 458 of the device 450, then through the air outlet 460 of the device 450, and then through the air inlet 502 of the cylinder 500. This air then circulates around the heater assembly 600 and travels toward the air outlet 504. This airflow entrains vapor formed by the liquid aerosol matrix heated by the first heating element 604 and the second heating element 605. Due to the generation of higher and lower temperature regions, as explained above, the vapor comprises different compounds with different boiling points in desired proportions. This entrained vapor then cools and condenses to form an aerosol. This aerosol is then delivered to the user via the air outlet 504.

[0207] Figure 5 A schematic cross-sectional view of the second heater assembly 600 is shown.

[0208] The first heating element 604 includes a first portion 606, a second portion 608, a third portion 610, a fourth portion 612, a fifth portion 614, a sixth portion 616, a seventh portion 618, an eighth portion 620, and a ninth portion 622. The first portion 606, the third portion 610, the fifth portion 614, the seventh portion 618, and the ninth portion 622 are embedded in the liquid aerosol forming matrix storage component 602. The second portion 608, the fourth portion 612, the sixth portion 616, and the eighth portion 620 are not embedded in the liquid aerosol forming matrix storage component 602. The second portion 608 and the eighth portion 620 are located in the airflow path between the air inlet 502 and the air outlet 504 of the cylinder 500. The fourth portion 612 and the sixth portion 616 are located in the liquid aerosol forming matrix storage container 603.

[0209] exist Figure 5 In the image, the varying thickness of the first heating element 604 can be observed. Compared to the rest of the first heating element 604, the central section of the fifth portion 614 has a reduced thickness. Specifically, the central section of the fifth portion 616 has a thickness approximately 30% of the thickness of the rest of the first heating element 604. Figure 5As shown, the fifth portion 614 also includes corrugations. The area surrounding the fifth portion 614 of the liquid aerosol forming matrix storage component 602 can be heated to a relatively higher temperature compared to other areas of the liquid aerosol forming matrix storage component 602. This is because the thinner fifth portion 614 of the heating element 604 allows the fifth portion 614 to be inductively heated to a higher temperature than other portions of the heating element 604. Alternatively or additionally, the corrugations in the fifth portion 614 mean that the area surrounding the fifth portion 614 of the liquid aerosol forming matrix storage component 602 includes a larger volume and a larger surface area of ​​the heating element 604 compared to other areas of the liquid aerosol forming matrix storage component 602 of similar size. Therefore, more heat is transferred from the heating element 604 to the area surrounding the fifth portion 614 of the liquid aerosol forming matrix storage component 602 compared to other areas.

[0210] Figure 6 A schematic perspective view of the second heater assembly 600 is shown. Figure 6 In this configuration, the second heating element 605 is visible. The second heating element 605 is identical to and positioned adjacent to the first heating element 604. Therefore, the second heating element 605 similarly has a portion embedded in the liquid aerosol forming matrix storage component 602, a portion located in the reservoir 603, and a portion located in the airflow path between the air inlet 502 and the air outlet 504 of the cylinder 500. Figure 6 In the middle, the second part 608 and the eighth part 620 of the first heating element 604 are also visible.

[0211] The heater assembly described herein can provide regions of higher and lower temperatures within a liquid aerosol forming matrix storage component. Alternatively or additionally, the heater assembly can provide regions within the liquid aerosol forming matrix storage component that increase in temperature at a greater rate and regions that increase in temperature at a lesser rate. Advantageously, as explained above, this allows liquid aerosol forming matrix compounds having higher and lower boiling points to evaporate simultaneously at desired rates.

[0212] For the purposes of this specification and the appended claims, unless otherwise specified, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein. Thus, in this context, the number A is understood as A ± 10% A. In this context, the number A can be considered to include a value within the general standard error for the measurement of the property modified by the number A. In some cases as used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of deviation from A does not significantly affect the fundamental and novel features of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein.

Claims

1. A heater assembly for an aerosol generation system, the heater assembly comprising: Liquid aerosol forming matrix storage component; as well as A free-flowing liquid aerosol forming matrix storage device, the storage device being in fluid communication with the liquid aerosol forming matrix storage component; The heating element comprises a first part, a second part, and another part. The first portion of the heating element is embedded in the liquid aerosol forming matrix storage component, the second portion of the heating element is not embedded in the liquid aerosol forming matrix storage component, and the other portion of the heating element is located in the storage container.

2. The heater assembly of claim 1, wherein the heating element comprises a third portion and a fourth portion, wherein the third portion of the heating element is embedded in the liquid aerosol forming matrix storage component and the fourth portion is not embedded in the liquid aerosol forming matrix storage component.

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

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

5. The heater assembly according to any one of claims 1 to 3, wherein the cross-section of the heating element varies along the length of the heating element.

6. The heater assembly according to any one of claims 1 to 3, wherein the heating element extends between a first end and a second end, and the heating element has a first cross-sectional area at a first point between the first end and the second end, a second cross-sectional area at a second point between the first point and the second end, and a third cross-sectional area at a third point between the second point and the second end, each of the first cross-sectional area and the third cross-sectional area being greater than or less than the second cross-sectional area.

7. The heater assembly according to any one of claims 1 to 3, wherein the heating element deflects into and out of the liquid aerosol forming matrix storage component.

8. The heater assembly according to any one of claims 1 to 3, wherein the heating element comprises one or more of a curved portion, an undulating portion, a folded portion, and a corrugated portion.

9. The heater assembly according to any one of claims 1 to 3, comprising a second heating element.

10. The heater assembly of claim 9, wherein the second heating element comprises a first portion and a second portion, wherein the first portion of the second heating element is embedded in the liquid aerosol forming matrix storage component and the second portion of the second heating element is not embedded in the liquid aerosol forming matrix storage component.

11. The heater assembly according to any one of claims 1 to 3, wherein, During use, both the first and second parts are heated to at least 50 degrees Celsius.

12. The heater assembly according to any one of claims 1 to 3, wherein, The other portion of the heating element is not embedded in the liquid aerosol forming matrix storage component.

13. An aerosol generation system comprising a heater assembly as described in any one of claims 1 to 12.

14. The aerosol generation system of claim 13, the aerosol generation system comprising an aerosol generation device and a cylinder including the heater assembly, wherein the cylinder is configured to engage with and disengage from the aerosol generation device.

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