Cartridge for an aerosol generation system

Abstract

A cartridge for use with an aerosol generating system, the cartridge comprising: a first compartment comprising a solid aerosol-forming material, and a second compartment comprising a liquid aerosol-forming material stored in a liquid retaining element, the liquid retaining element comprising loosely packed solid particles configured to retain the liquid aerosol-forming material in interstitial gaps of the particles and on surfaces of the particles; and an air permeable separating element separating the solid aerosol-forming material in the first compartment from the liquid aerosol-forming material in the second compartment. The first compartment is disposed downstream of the second compartment, such that one or more constituent components of the solid aerosol-forming material disposed within the first compartment are injected into aerosol vapour generated in the second compartment during passage of the aerosol vapour through the solid aerosol-forming material. The loosely packed solid particles are flexibly interconnected, thereby enabling flexible design and simple manufacture of the liquid retaining element.

Description

Technical Field

[0001] This invention relates to an electronic aerosol generating system for producing inhalable aerosols, such as electronic cigarettes or e-cigarettes, and more particularly to an electronic aerosol generating system that generates aerosol vapor by generating heat through electricity. Specifically, this invention relates to a cartridge for use in an aerosol generating system comprising solid and liquid aerosol forming materials. Background Technology

[0002] Personal aerosol generating systems, also known as electronic cigarettes or e-cigarettes, produce aerosols without burning tobacco and are considered an alternative to conventionally burning tobacco products such as cigarettes, cigars, and pipes. The use of electronic aerosol generating systems has become widespread due to the health concerns associated with conventional smoking products (such as the production of well-known harmful chemical byproducts associated with the combustion of smoking products, including carbonyl compounds and carbon monoxide).

[0003] A personal aerosol generating system is a battery-powered portable inhaler system that includes a mouthpiece, a heating chamber that receives and heats aerosol-forming material, a vaporization unit, typically a heating element, a power supply unit, and an electronic control unit. Vaporization occurs when the aerosol-forming material is heated to a temperature equal to or higher than its vaporization temperature. An example of a conventional aerosol generating system can be configured to vaporize a liquid aerosol-forming material, such as a nicotine-containing liquid stored in a liquid reservoir. The liquid reservoir can be configured as a disposable component, taking the form of a cartridge that may further include a heating element. Alternatively, the liquid reservoir can be non-removably integrated into the aerosol generating device, wherein the liquid reservoir is configured to be refilled once the aerosol-forming material is depleted.

[0004] Aimed at providing users with an experience that more closely simulates smoking, some devices combine liquid aerosol-forming materials with solid aerosol-forming materials (such as tobacco-based matrices) to impart a tobacco flavor to the aerosol to be inhaled. In such aerosol generation systems, aerosol vapor generated by the liquid aerosol-forming material is delivered through the solid aerosol-forming material when heated by a heating element, causing aerosols from the solid aerosol-forming material to be entrained in the vapor. Such cartridge configurations are disclosed, for example, in EP3145349B1, EP3145349B1, and EP3554291A1. In the aerosol generation systems described above, the cartridge stores the liquid aerosol-forming material and the solid aerosol-forming material separately in a first and a second part of the cartridge to prevent these aerosol-forming materials from mixing within the cartridge. In such cartridges, the compartment for storing the liquid aerosol-forming material includes a liquid retention element, such as a porous material, typically porous glass or ceramic, foam, sponge, or fiber wicking material. Simultaneously, in the cartridge, a compartment for storing liquid aerosol-forming material is positioned upstream of the compartment for storing solid aerosol-forming material, such that aerosol vapor generated by the liquid aerosol-forming material is delivered to the mouthpiece air outlet through the solid aerosol-forming material. The cartridge may include a heating element for heating the liquid aerosol-forming material. The heating element may be integrated into the liquid retention element. Alternatively, the heating element may be a separate, removable element attached to a reusable portion of the aerosol generation system and can be inserted into the liquid retention element during use.

[0005] In this case, the liquid retention element further includes a cavity configured to receive a heater when the cartridge is inserted into the device, which can complicate the manufacturing process. Manufacturing the cavity in a porous material can be challenging because porous materials can fracture under stress. The manufacturing process may also generate residual particles, which could pose safety concerns during e-cigarette use. The brittle nature of porous materials may further limit the design of the liquid retention element.

[0006] It may be desirable to provide a simple and relatively easy-to-manufacture cartridge configuration. It may also be desirable for the cartridge to include fewer components to be set up or more reusable components to reduce environmental impact. Summary of the Invention

[0007] According to a first aspect of the invention, a cartridge for an aerosol generating system is provided, the cartridge comprising: a cartridge shell divided into a first compartment and a second compartment; a first compartment comprising a solid aerosol forming material; a second compartment comprising a liquid aerosol forming material, wherein the liquid aerosol forming matrix comprises loosely-packed solid particles configured to retain aerosol forming liquid in the gaps between the particles and / or on the surface of the particles; and an air-permeable separation element disposed between the first compartment and the second compartment.

[0008] A liquid aerosol forming matrix, comprising loosely packed solid particles, absorbs the liquid aerosol generating material, thereby forming aggregated particles. In this way, the loosely packed solid particles retain the liquid aerosol generating material in the gaps between adjacent particles and prevent liquid leakage into the first compartment. The liquid aerosol generating material can be stored in a second compartment without mixing with the solid aerosol generating material stored in the first compartment.

[0009] An air-permeable separation element disposed between the first and second compartments allows aerosol vapors generated by the liquid aerosol generating material in the second compartment to pass through the air-permeable element to the first compartment containing the solid aerosol forming material, while preventing direct contact between the solid aerosol generating material in the first compartment and the liquid aerosol generating material in the second compartment during storage and use of the device.

[0010] In another aspect of the invention, an aerosol generating system may include: a cartridge; and an aerosol generating device comprising: a cavity for receiving at least a portion of the cartridge; a heating device configured to heat at least a portion of a liquid aerosol forming material in a second compartment of the cartridge; a power source; and a controller for controlling the power supply from the power source to the heating element.

[0011] The heating device may include a heating element disposed within the cavity of the aerosol generating device, such that the heating device is located near a first compartment of the aerosol generating device. In use, at least a portion of the first compartment is heated by the heating element to a temperature at or above the vaporization temperature of the liquid aerosol generating material stored in the first compartment. In this manner, as aerosol vapor passes through the first compartment from the second compartment, the aerosol generated in the second compartment is subsequently injected into one or more components of the solid aerosol forming material stored in the first compartment.

[0012] The heating device may include an elongated heating element disposed at the distal end of the cavity of the aerosol generating device. The elongated heating element may be a blade-shaped heating element. The blade-shaped heating element may be a resistance heating element. Alternatively, the heating element may be a sensor element. The heating element is configured to penetrate a portion of the first compartment of the cartridge when the cartridge is inserted into the cavity of the aerosol generating device.

[0013] In this configuration, the cartridge may include a pierceable seal configured to be penetrated by a heating element when the cartridge is inserted into the aerosol generating device. The pierceable seal may extend through the upstream end of the cartridge.

[0014] The heating element is preferably made of titanium or stainless steel. Examples of other suitable materials include nickel alloys, chromium alloys, aluminum alloys, and iron alloys.

[0015] In any example of the liquid retention element comprising loosely packed solid particles according to the invention, the liquid on the surface causes particle cohesion, and the liquid forms bridges between adjacent particles to connect them, allowing the loosely packed solid particles to have flexible interconnections between them. This allows the particles comprising the liquid retention element to conform to a heating element inserted into a cartridge. During insertion of the heating element by penetrating a pierceable seal attached to the cartridge, the loosely packed solid particles can rearrange their alignment to accommodate the shape of the heating element. Compared to using monolithic porous materials that require a cavity to house the heating element, this feature can reduce the complexity of the cartridge manufacturing process, reduce the production cost of cartridges, and improve the versatility of cartridges.

[0016] The inclusion of loosely packed granules in the liquid retention element also allows for a reduced risk of damage to the liquid retention structure during heating element insertion. Furthermore, because the liquid retention structure can be adapted to fit the shape of the heating element, heat transfer from the heating element to the e-liquid can be improved. Additionally, this feature may be advantageous in terms of the reusability of the cartridge material compared to liquid retention elements formed from monolithic porous materials, as the granules can be relatively easily broken down, for example, by dispersing the loosely packed solid granules into the liquid. As described later, any cleaning process established for the solid granules can be used to clean the individually broken-down granules.

[0017] Alternatively, the cartridge can be configured to be inductively heated. In this case, the aerosol generating device includes an induction coil configured to heat a second compartment of the cartridge inserted into the heating chamber of the aerosol generating device.

[0018] In an aerosol generation system in which the liquid aerosol forming material is vaporized by induction heating, the second compartment may further include a sensor element.

[0019] The sensor element may include inductively heated materials in the form of strips, disks, rings, plates, particles, sheets, and coils.

[0020] Suitable materials for sensor elements can be ferromagnetic metals, alloys, and oxides, such as iron, nickel, cobalt, iron alloys, nickel alloys, cobalt alloys, ferrites, or any other conductive metals and alloys, such as aluminum and stainless steel.

[0021] Preferably, the sensor element is embedded in a liquid aerosol forming matrix to achieve efficient heat transfer. The sensor element may include particles, sheets, strips, discs, etc., mixed with loosely packed solid particles of the liquid aerosol forming matrix.

[0022] Alternatively, the sensor element may be disposed around at least a portion of the liquid aerosol forming matrix. The housing of at least a portion of the second compartment generated by the aerosol may include sensor material.

[0023] Solid aerosol forming materials may include tobacco or tobacco-derived materials. Solid aerosol forming materials may include tobacco beads, powder, fragments, strips, reconstituted tobacco materials, cast tobacco sheets, or any combination thereof.

[0024] An air-permeable separation element includes one or more pores, holes, or air channels penetrating the thickness of the air-permeable separation element to physically separate the solid aerosol-forming material in the first compartment from the liquid aerosol-forming material retained within the loosely packed solid particles in the second compartment, while establishing aerosol transfer between the first and second compartments. Preferably, the air-permeable separation membrane is a mesh, a perforated plate, a thin film or foil, or an air-permeable membrane. Preferably, the pores, holes, or air channels of the air-permeable element are small enough to substantially block all individual particles of the loosely packed particles in the liquid retention element.

[0025] The air-permeable separation membrane can be made of stainless steel, titanium, heat-resistant polymer, PTFE, PEEK, or any material that is stable at the operating temperature of the aerosol generation system and chemically inert to the aerosol-forming material stored in the cartridge and to any chemical compounds generated by the aerosol-forming material during use. In this way, the liquid aerosol-forming material can be stored in the second compartment without undergoing any unintended chemical reactions.

[0026] Loose solid particles include beads, flakes, fragments, fibers, or any combination thereof.

[0027] Preferably, the loosely packed solid particles are stable at at least up to the vaporization temperature of the liquid aerosol forming material. Preferably, the surface of at least the loosely packed solid particles is thermally stable at at least up to 350°C. Preferably, the surface of the loosely packed solid particles, or at least the loosely packed solid particles, comprises a material that is chemically inert to the liquid aerosol forming material.

[0028] Chemically inert surfaces prevent the particles from undergoing chemical reactions, or prevent the particles from acting as catalysts to initiate undesirable chemical reactions during cartridge storage and vaporization. A chemically inert surface can be the chemically inert surface of the solid particles themselves. Alternatively, a chemically inert surface can be a chemically inert coating encapsulating each solid particle. In this document, chemical inertness is understood in relation to the chemicals stored in the cartridge and the chemicals generated during the heating of the aerosol-forming matrix.

[0029] Chemically inert coatings and particles should withstand temperatures at least as high as those used to vaporize aerosol-forming materials.

[0030] Preferably, the loosely packed solid particles include a hydrophilic surface. In this way, the liquid aerosol generating material can be effectively retained in the gaps and surfaces of the particles.

[0031] The hydrophilic surface of the particles can be the surface of the solid particles themselves. Alternatively, the surface of the particles can be coated with a hydrophilic coating, or the surface of the particles can be grafted with a chemical compound that includes hydrophilic functional groups such as hydroxyl, carboxyl, carbonyl, amino, mercapto, and phosphate groups.

[0032] Suitable materials for loosely packed solid particles may include silica, zeolite, glass or quartz, or any combination thereof.

[0033] Advantageously, the surface of the particles can be porous, which allows for an increase in the amount of liquid stored in the liquid retention structure.

[0034] Preferably, the loosely packed solid particles comprise particles with a maximum size at least equal to or less than about 2 mm. For example, the maximum size of the beads can range from about 100 μm to about 1 mm, or from about 200 μm to about 800 μm, preferably from about 250 μm to about 600 μm. For example, the maximum size is about 500 μm. The maximum size of the loosely packed solid particles is substantially uniform. In this way, the size of the gap between adjacent particles is substantially uniform, which allows capillary forces to produce uniform liquid delivery on the liquid retention element.

[0035] Advantageously, cartridges comprising loosely packed solid particles for retaining liquid aerosol-forming materials can be recyclable after use. Because the loosely packed solid particles are not rigidly interconnected, the particles can be easily separated from the cartridge casing and heating element, and can be broken down into individual particles, for example, by dispersing the particles in a liquid. The broken-down individual particles can be cleaned by any suitable method for cleaning the particles, and these particles can be reused. Since conventional liquid retention materials (such as porous materials, microfiber materials, and sponges) are generally difficult to clean due to their complex structures, the use of loosely packed solid particles allows for a simple recycling process.

[0036] One example of a method for recycling e-cigarette cartridges includes the following steps: separating loosely packed solid particles from the used cartridge; dispersing the used particles in a suitable cleaning solution to remove residues of the liquid aerosol forming material; filtering to separate the particles from the cleaning solution; dispersing the particles in a rinsing solution; filtering to separate the particles from the rinsing solution; drying the particles; and collecting the particles for reuse. The cleaning method may further include a dry cleaning step (e.g., plasma cleaning and thermal cleaning). Optionally, the cleaned particles may be hydrophilically treated to improve the wettability of the liquid aerosol forming material. Attached Figure Description

[0037] Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which:

[0038] Figure 1 A cross-sectional view of a tobacco cartridge in an embodiment of the present invention is shown.

[0039] Figure 2 A cross-sectional view of an aerosol generating device is shown, which is configured to receive... Figure 1 The smoke cartridge shown.

[0040] Figure 3 A cross-sectional view of an aerosol generation system is shown, the system including a housing in Figure 2 aerosol generating device Figure 1 The e-cigarette cartridges.

[0041] Figure 4 A cross-sectional view of a tobacco cartridge according to another embodiment of the present invention is shown.

[0042] Figure 5 A cross-sectional view of an aerosol generating device is shown, which is configured to receive... Figure 4 The smoke cartridge shown.

[0043] Figure 6 A cross-sectional view of an aerosol generation system is shown, the system including a housing in Figure 5 aerosol generating device Figure 4 The e-cigarette cartridges.

[0044] Figure 7 An example of a method for recycling e-cigarette cartridges is shown. Detailed Implementation

[0045] Figures 1 to 3 An aerosol generating system 1 is shown, comprising a cartridge 10 and an aerosol generating device 30 according to an embodiment of the invention. The cartridge is configured to be received in a heating chamber 35 of the aerosol generating device 30. The cartridge 10 and the aerosol generating device 30 can be detachably coupled in a functional relationship. Various different mechanisms can be used to connect the cartridge and the aerosol generating device, including threaded connections, press-fit connections, interference fits, magnetic connections, etc. When the cartridge 10 and the aerosol generating device 30 are assembled, the aerosol delivery system 1 can be generally rod-shaped.

[0046] Figure 1 A cartridge 10 separated from an aerosol generating device 30 is shown. The cartridge 10 includes a cartridge housing 11 and an air-permeable separation element 16 that divides the internal volume of the cartridge housing 11 into a first compartment 12 and a second compartment 13. Referring to an airflow direction A, the first compartment 12 is located downstream of the second compartment 13. The first compartment 12 includes a solid aerosol forming matrix 20, and the second compartment 13 includes a liquid aerosol forming matrix 21.

[0047] The cartridge casing 11 includes a tubular body 22, an upstream end 18, and a downstream end 17.

[0048] The downstream end 17 of the cartridge 10 may include a filter 15. The filter 15 retains the solid aerosol forming matrix 20 within the cartridge housing 11. The filter may include a rod or plug made of filter material such as cellulose acetate tow and polylactic acid fiber.

[0049] The upstream end 18 of the cartridge shell 11 is a closed end. The closed end includes a piercing element 16. The piercing element 16 is attached to the cartridge shell 11 such that when the cartridge 10 is inserted into the heating chamber 35 of the aerosol generating device 30, the piercing element 16 is penetrated by the heating element 32 of the aerosol generating device 30.

[0050] The downstream end 17 of the cartridge housing 11 may include a mouthpiece 19, which is detachably attached to the downstream end 17 of the cartridge 10. The mouthpiece 19 defines at least one airflow passage including at least one air outlet. The air outlet is in fluid communication with the air outlet of the cartridge via a filter 15, which may be integrated into the mouthpiece 19. Although Figure 1The example shown depicts a mouthpiece attached to the distal end of the cartridge, but alternatively, the mouthpiece 19 may be detachably attached to a portion of the housing of the aerosol generating device 30, such that the mouthpiece covers the air outlet on a filter located at the downstream end of the cartridge. Alternatively, the mouthpiece 19 may be part of the cartridge 10. In use, the user draws air from the mouthpiece, causing air to flow from the air inlet of the aerosol generating device through the cartridge into the aerosol generating system 1.

[0051] An air-permeable separation element 14 is disposed within the internal volume of the tubular cartridge housing 11 to divide it into a first compartment 12 and a second compartment 13. Preferably, the air-permeable element 14 is in the form of a disc. The diameter of the disc is approximately the inner diameter of the cartridge housing, such that the air-permeable separation element fits within the internal tubular body of the air-permeable separation element. In this way, the first compartment 12 and the second compartment 13 are defined by the inner wall of the cartridge housing 11 and the surface of the air-permeable element 14. The air-permeable separation element 14 may include a mesh or a perforated plate. The air-permeable separation element may be positioned substantially perpendicular to the longitudinal axis of the cartridge body 200, wherein the separation element can provide physical separation between the first compartment 12 and the second compartment 13 while maintaining aerosol vapor communication between them.

[0052] The first compartment 12 is located downstream of the tubular body 22 of the cartridge, and the second compartment 13 is located upstream of the tubular body of the cartridge 10. The first compartment contains a solid aerosol forming matrix 20, which includes solid aerosol forming material 23, while the second compartment contains a liquid aerosol forming matrix 21, which includes a liquid retention element 25 and liquid aerosol forming material 27 stored in the liquid retention element 25. The liquid retention element 25 includes loosely packed solid particles 26.

[0053] The loosely packed particles 26 are granular materials, which are aggregates (or clusters) of small, solid particles visible to the naked eye. When the particles are wetted by a liquid, microscopically visible liquid bridges are formed in the gaps between adjacent particles. The capillary forces of these liquid bridges hold the aggregated particles together. Therefore, the particle network is flexible and reconfigurable when mechanical stress is applied. When a large solid component (e.g., heater blades) is inserted into the agglomerate, the particles move to change their alignment to fit the shape of the heater.

[0054] Preferably, the loosely packed solid particles 26 comprise particles with a maximum size at least equal to or less than about 2 mm. For example, the maximum size of the beads can range from about 100 μm to about 1 mm, or from about 200 μm to about 800 μm, preferably from about 250 μm to about 600 μm. For example, the maximum size is about 500 μm. The maximum size of the loosely packed solid particles 26 is substantially uniform. In this way, the size of the gap between adjacent particles 26 is substantially uniform, which allows capillary forces to produce uniform liquid delivery on the liquid retention element.

[0055] When describing "maximum size," for example, in the case of elongated particles resembling rods, the maximum size is the length of the rod. For particles with an elliptical cross-section, the maximum size is the largest diameter along the major axis. In the case of roughly spherical particles, the maximum size corresponds to the diameter.

[0056] Preferably, the loosely packed solid particles 26 are stable at at least up to the vaporization temperature of the liquid aerosol forming material, for example up to 350°C.

[0057] In the context of this specification, a material is "stable" when its properties do not change or at least do not undergo any significant changes. Material properties include, for example, phase (solid, liquid, gas), mechanical properties (strength, hardness, etc.), crystal structure, and chemical properties (chemical composition, chemical structure of constituent components, etc.).

[0058] Preferably, the surface of the loosely packed solid particles 26 or at least the loosely packed solid particles 26 comprises a material that is chemically inert to the liquid aerosol forming material.

[0059] A chemically inert surface can be the chemically inert surface of the solid particles themselves. Alternatively, a chemically inert surface can be a chemically inert coating that encapsulates each solid particle. In this document, chemical inertness is understood in relation to the chemicals stored in the cartridge and the chemicals generated during the heating of the aerosol-forming matrix.

[0060] The chemically inert coating and particles should withstand temperatures at least up to 27°C for vaporizing aerosol-forming materials.

[0061] The loosely packed solid particles 26 are configured to retain the aerosol-forming liquid within the gaps between the particles and on the surface of the particles. Specifically, as described above, the particles aggregate together through liquid bridges formed between them. This phenomenon, in turn, retains the liquid within the aggregated particle structure. The absorption capacity is related to the volume of the liquid bridges formed in the gaps between adjacent particles, which also determines the particle aggregation force.

[0062] The liquid aerosol forming material 27 includes an aerosol forming agent. Suitable aerosol forming agents include polyols or mixtures thereof, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerol. The liquid aerosol forming matrix may include water, solvents, ethanol, plant extracts, and natural or artificial flavorings.

[0063] The liquid aerosol forming material 27 includes a tobacco-containing material comprising volatile tobacco flavor compounds released from the liquid upon heating. Preferably, the liquid aerosol forming matrix may comprise a non-tobacco material. The liquid aerosol forming material 27 may be nicotine-free. Alternatively, the liquid aerosol forming matrix may comprise nicotine.

[0064] The solid aerosol forming material 23 of the solid aerosol forming matrix 20 may include tobacco or tobacco-derived materials, such as tobacco leaves or reconstituted tobacco in the form of particles, sheets, strips, fragments, pellets, or any other form of tobacco material. The solid aerosol forming matrix 20 may be an inflatable tobacco mousse or an equivalent tobacco foam.

[0065] The solid aerosol forming matrix 20 may include non-tobacco materials, such as flavoring agents in the form of particles, capsules, gels, or any other form of flavoring agent. The solid aerosol forming matrix 20 may include tobacco-containing materials and tobacco-free materials.

[0066] In the context of this specification, tobacco-containing materials can be tobacco leaves, powdered tobacco plants, tobacco mousse, reconstituted tobacco materials, and any form of tobacco material.

[0067] The solid aerosol forming matrix 20 may include at least one aerosol forming agent. Suitable aerosol forming agents include, but are not limited to: polyols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerol; esters of polyols, such as glyceryl monoacetate, glyceryl diacetate, or glyceryl triacetate; and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate. Preferred aerosol forming agents may include propylene glycol and glycerol.

[0068] Figure 2An aerosol generating device 30 is shown. The aerosol generating device 30 includes a housing 31, a heating chamber 35 defined by the housing 31, a heating element 32, a power supply 33, and a controller 34. The heating chamber 35 is configured to receive at least a portion of a second compartment 13 of a cartridge 10 by inserting a cartridge 10 along the longitudinal axis of the aerosol generating device 30. The heating element 32 is disposed at the bottom end 36 (or distal end) of the heating chamber 35. The heating element 32 extends into the heating chamber 35. Preferably, the heating element 32 is disposed approximately at the center of the cross-section of the heating chamber 35. The longitudinal axis of the heating element 32 can be aligned with the longitudinal axis of the aerosol generating device 30. The housing 31 of the aerosol generating device 30 further includes at least one airflow inlet (not shown) in fluid communication with an air inlet passage of the cartridge 10.

[0069] When using, such as Figure 3 As shown, the upstream portion of the smoke cartridge 10 (corresponding to the portion of the second compartment 13) is inserted into the heating chamber 35 of the aerosol generating device 30. Although the housing 31 of the aerosol generating device 30 extends to cover... Figure 3 The example shown is a portion of the second compartment, but the housing may extend to at least a portion of the first compartment or the housing may extend to the downstream end 17 of the cartridge, such that the cartridge is completely disposed within the heating chamber 35.

[0070] During insertion of the cartridge 10, the pierceable element 16 on the cartridge 10 is pierced by the heating element 32, thereby allowing the heating element 32 to be inserted into the second compartment 13. When the heating element 32 is inserted into the liquid aerosol forming matrix 21, the loosely packed solid particles 26 immediately reconfigure their arrangement to fit the shape of the heating element. When the cartridge 10 is fully inserted into the heating chamber 35, the heating element 32 is positioned within the second compartment 13. The length of the heating element 32 is shorter than the longitudinal length of the second compartment 32 of the cartridge 10, so that the heating element 32 inserted into the cartridge 10 does not extend beyond the second compartment 13.

[0071] Preferably, the volume of the liquid aerosol forming matrix 21 stored in the second compartment 13 is less than the internal cavity volume of the second compartment 13, such that during or after the insertion of the heating element into the cartridge, the total volume of the liquid aerosol forming matrix 21 and the inserted portion of the heating element 32 does not exceed the internal cavity volume of the second compartment 13.

[0072] When the heating element 32 is activated, the liquid aerosol forming matrix 21 (which comprises liquid aerosol forming material 27 and loosely packed particles 26 retaining the liquid aerosol forming material 27) is heated to a temperature at or above the vaporization temperature of the liquid aerosol forming material 27. The vapor generated in the second compartment 13 is then mixed with air from the air inlet and delivered through the first compartment 12 to the air outlet of the filter 15. During the passage of the air and vapor mixture through the solid aerosol forming matrix 20 in the first compartment 12, aerosols from the solid aerosol forming matrix 20 are entrained in the air and vapor mixture.

[0073] Figure 4 A cross-sectional view of a cartridge 40 according to another embodiment of the invention is shown. In this embodiment, the second compartment 43 of the cartridge 40 further includes a sensor element 44 configured to heat the liquid aerosol forming matrix 21. The sensor element 44 may comprise an inductively heatable material in the form of, for example, strips, discs, rings, plates, particles, sheets, and coils. Suitable materials for the sensor element may be ferromagnetic metals, alloys, and oxides, such as iron, nickel, cobalt, iron alloys, nickel alloys, cobalt alloys, ferrites, or any other conductive metal and alloy, such as aluminum or stainless steel. In this example, the sensor element 44 comprises three annular sensor plates 44a, 44b, 44c, but any number of sensor devices may be used, and the type of sensor may be any other form, such as discs, strips, plates, or combinations thereof. Preferably, the sensor element 44 is embedded in the liquid aerosol forming matrix 21 for efficient heat transfer. The sensor element may comprise particles, sheets, strips, discs, etc., mixed with loosely packed solid particles of the liquid aerosol forming matrix. Alternatively, the sensor element may be disposed around at least a portion of the liquid aerosol forming matrix. The housing of at least a portion of the second compartment generated by the aerosol may include sensor material.

[0074] The cartridge housing 41 may include one or more air inlet channels (not shown) configured to deliver air into the second compartment 43. The air inlet channels may be disposed within the tubular body of the cartridge housing 41.

[0075] Figure 5 An aerosol generating device 50 is shown, which is configured to receive... Figure 4The aerosol generating device 50 includes a cartridge 40. The aerosol generating device 50 includes a heating chamber 55, an induction coil 52, a power supply 33, and a controller 34. The heating chamber 55 is configured to receive at least a portion of a second compartment 43 of the cartridge 40 by inserting the cartridge 40 along the longitudinal axis of the aerosol generating device 50. The induction coil 52 is configured to transfer energy to a sensor element 44 in the cartridge 40 by induction heating. The induction coil 52 is arranged such that when the cartridge 40 is inserted into the heating chamber 55, the coil is positioned near the second compartment 43 (liquid aerosol forming matrix 21) of the cartridge 40. The induction coil 52 may be embedded in a housing 51, typically in a tubular sidewall portion of the heating chamber 55. In this example, the induction coil extends from an upstream end to a downstream end of the second compartment. The housing 51 of the aerosol generating device 50 further includes an airflow inlet (not shown) in fluid communication with an air inlet passage of the cartridge 40.

[0076] When using, such as Figure 6 As shown, the second compartment 43 of the cartridge 40 is inserted into the heating chamber 55 of the aerosol generating device 50. When the cartridge 40 is fully inserted into the heating chamber 55, the induction coil 52 surrounds at least a portion of the liquid aerosol forming matrix 21 in the second compartment 55 of the cartridge 50.

[0077] When induction coil 52 is activated, power from power source 33 is delivered to the induction coil. Controller 34 controls the delivery of power to induction coil 52 at a certain frequency, thereby allowing induction coil 52 to generate an electromagnetic field to heat sensor element 44 at or above a target temperature. While heating sensor element 44, at least a portion of the liquid aerosol forming matrix is ​​heated at or above a temperature that vaporizes the liquid aerosol forming material stored in liquid aerosol forming matrix 21. The vapor generated in the second compartment 43 is then mixed with air flowing through the smoke cartridge 40. The mixture of vapor and air from liquid aerosol forming matrix 21 is then passed through an air-permeable separation element 14 to the first compartment 42. During the passage of the mixture of air and aerosol vapor through solid aerosol forming matrix 20 in the first compartment, aerosols from solid aerosol forming matrix 20 are entrained in the mixture of air and aerosol vapor. The mixture of air and aerosol vapor passes through the first compartment 42, through the filter 15, and is delivered to the air outlet at the downstream end 47 of the smoke cartridge 40.

[0078] Because the loosely packed solid particles in the liquid aerosol forming matrix are not rigidly interconnected, they can be separated, for example, by dispersing the particles into the liquid. This is advantageous for the reusability of the cartridge, as the individually separated particles can be effectively cleaned using any cleaning method established for small particles.

[0079] Figure 7An example of a method for recycling a cartridge comprising loosely packed solid particles is shown according to one embodiment. The method described below is intended to be illustrative only, and the method may include alternative steps or one or more additional steps.

[0080] In step 60, the used cartridge is provided. The loosely packed solid particles forming the liquid retention structure can then be removed from the cartridge casing and collected in a container including a filter element (step 61). The container may be a basket comprising a metal mesh, metal wire, or plastic mesh.

[0081] Subsequently, the loosely packed solid particles in the container are cleaned in a cleaning liquid (step 62). The particles are immersed and dispersed in a suitable cleaning solution to remove residues of the liquid aerosol forming material and any chemical compounds generated during the use of the cartridge.

[0082] The container containing the particles is then removed from the cleaning liquid and placed in a rinsing solution (step 64) to remove any residual cleaning solution from the particles. The cleaning and rinsing steps can be repeated. These steps can be performed in combination with ultrasonic vibration.

[0083] The particles are then dried (step 65). The cleaning method may further include one or more additional steps of a drying cleaning process (such as plasma cleaning or thermal cleaning, or a combination thereof). Optionally, the cleaned particles may be hydrophilically treated to improve the wettability of the e-liquid.

Claims

1. A cartridge for an aerosol generating system, the cartridge comprising: The cartridge casing is divided into a first compartment and a second compartment; The first compartment includes a solid aerosol forming material; The second compartment includes a liquid aerosol forming matrix, wherein the liquid aerosol forming matrix includes a liquid retention structure comprising loosely packed solid particles configured to retain liquid aerosol forming material in the gaps between the particles and / or on the surface of the particles. as well as An air-permeable separation element is disposed between the first compartment and the second compartment.

2. The e-cigarette cartridge according to claim 1, wherein, The solid aerosol forming material includes tobacco or tobacco-derived materials.

3. The e-cigarette cartridge according to claim 1, wherein, The air-permeable separation element is a mesh, a perforated plate, a foil, or an air-permeable membrane, configured to physically separate the solid aerosol forming material in the first compartment from the liquid aerosol forming material retained within the loosely packed solid particles in the second compartment, while establishing aerosol transfer between the first and second compartments.

4. The e-cigarette cartridge according to claim 1, wherein, At least the surfaces of these loosely packed solid particles are stable at least at the vaporization temperature of the liquid aerosol forming material.

5. The smoke cartridge according to claim 4, wherein, At least the surfaces of these loosely packed solid particles are thermally stable at at least 350°C.

6. The e-cigarette cartridge according to claim 1, wherein, At least the surfaces of these loosely packed solid particles include materials that make the liquid aerosol forming material chemically inert.

7. The e-cigarette cartridge according to claim 1, wherein, These loosely packed solid particles include beads, flakes, fragments, or any combination thereof.

8. The e-cigarette cartridge according to claim 1, wherein, These loosely packed solid particles include hydrophilic surfaces.

9. The e-cigarette cartridge according to claim 1, wherein, These loosely packed solid particles include silica, zeolite, glass or quartz, or any combination thereof.

10. The e-cigarette cartridge according to claim 1, wherein, These loosely packed solid particles include particles with a maximum size of at least equal to or less than 2 mm.

11. The e-cigarette cartridge according to claim 1, wherein, The cartridge includes a puncture-resistant seal disposed on the cartridge casing in the second compartment.

12. The cigarette cartridge according to any one of claims 1 to 9, wherein, The second compartment includes a sensor element that can be inductively heated.

13. An aerosol generation system, the aerosol generation system comprising: The smoke cartridge according to any one of claims 1-12; as well as Aerosol generating apparatus, the aerosol generating apparatus comprising: A cavity for receiving at least a portion of the cartridge; A heating device configured to heat at least a portion of the liquid aerosol forming matrix in the second compartment of the cartridge; and Power supply; and A controller that controls the power supply from the power source to the heating device.

14. The aerosol generation system according to claim 13, wherein, The cartridge includes a puncturable seal disposed on the cartridge shell of the second compartment, and the heating device includes an elongated heater configured to penetrate the puncturable seal and insert into the second compartment when the cartridge is received in the cavity of the aerosol generating device.

15. The aerosol generation system according to claim 13 or 14, wherein, The heating device of the aerosol generating apparatus includes an induction coil located near the second compartment of the cartridge when the cartridge is received in the cavity of the aerosol generating apparatus.

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