Aerosol generating device and heater assembly

Abstract

An aerosol-generating device (500) for coupling to a cartridge, the aerosol-generating device (500) comprising a cartridge coupling portion for engaging a cartridge containing an aerosol-forming substrate. The aerosol-generating device (500) further comprises an airflow passage defined between the air inlet (510) and the air outlet (520); and a heater assembly. The heater assembly includes a fluid permeable heating element (540) configured to heat the aerosol-forming substrate from the cartridge. The heater assembly includes a first side and a second side opposite the first side, where the first side forms at least a portion of a surface of the wall of the airflow passage, and where the second side forms a portion of the cartridge coupling portion and is configured to contact the cartridge to receive the aerosol-forming substrate.

Description

[0001] The present disclosure relates to an aerosol generating device for coupling to a cartridge; a heater assembly for an aerosol generating device; a cartridge; and an aerosol generating system.

[0002] Aerosol generating systems configured to generate inhalable aerosols from aerosol-forming substrates are known in the art. Many previous aerosol generating systems include an aerosol generating device that can be connected to a tube. A typical tube used with an aerosol generating device includes an aerosol-forming substrate and a heater assembly, wherein the heater assembly includes a heating element. The tube may also include a wicking material adjacent to or in contact with the aerosol-forming substrate and the heating element. The wicking material is configured to deliver the aerosol-forming substrate to the heating element. In use, the heating element is configured to evaporate the aerosol-forming substrate. An airflow is arranged to pass through the heating element to entrain the generated vapor. In the airflow, the vapor condenses and forms an aerosol. Then the user can inhale the aerosol. The tube is removably connected to the aerosol generating device. The aerosol generating device generally includes a power supply, which is configured to supply power to the heating element via an electrical connector.

[0003] In an aerosol generating system of this type, it is desirable to minimise the amount of power required to heat the aerosol-forming substrate. This is particularly desirable in portable aerosol generating systems where the system comprises a portable power source such as a battery. In order to minimise power usage and to efficiently heat the aerosol-forming substrate, the heating element may be in direct contact with the wicking material and hence the aerosol-forming substrate.

[0004] Repeated use of an aerosol generating system in many heating cycles requires repeated heating of the wicking material. This may cause the wicking material to degrade over a period of time. The degradation may be caused by the heating of the wicking material. The degradation may also be caused by chemical interactions between the aerosol-forming substrate and the wicking material, mechanical stress on the wicking material, and particle accumulation on the surface of the wicking element. The degradation of the wicking material may lead to undesirable effects, such as inefficient heat transfer between the heating element and the wicking material, inefficient transfer of the aerosol-forming substrate from the wicking material to the heating element, or the generation of an aerosol including unfavorable components. In addition, during the use of the aerosol generating system, hot spots may occur in the heating element. Hot spots are areas of the heating element where the temperature is higher than the average temperature of the heating element during operation. These hot spots may lead to degradation of the wicking material.

[0005] The wicking material limits the life of any cartridge due to degradation.

[0006] It would be desirable to provide aerosol generating systems and aerosol generating devices for use in such systems which require less frequent disposal of the heater assembly.

[0007] According to a first aspect of the present disclosure, an aerosol generating device for coupling to a cartridge is provided. The aerosol generating device may include a cartridge coupling portion for engaging a cartridge containing an aerosol-forming substrate. The aerosol generating device may include an airflow path defined between an air inlet and an air outlet. The aerosol generating device may also include a heater assembly, the heater assembly including a fluid-permeable heating element, the fluid-permeable heating element configured to heat an aerosol-forming substrate from the cartridge, wherein the heater assembly includes a first side and a second side, the first side being opposite to the second side, wherein the first side forms at least a portion of a surface of a wall of the airflow path, and wherein the second side forms a portion of the cartridge coupling portion and is configured to contact the cartridge to receive the aerosol-forming substrate.

[0008] The heater assembly may be arranged within the device to be coupled to the cartridge. The aerosol generating device may be reusable. The cartridge may be disposable. Advantageously, when the cartridge needs to be disposed of, the cartridge may be separated from the device, disposed of and replaced. The heater assembly may remain in the device, rather than being removed and disposed of. Thus, the heater assembly may be reusable. The heater assembly may be more expensive to manufacture than the elements of the cartridge, so it is advantageous to prevent unnecessary disposal of the heater assembly.

[0009] The air inlet may be defined in a side wall of the device. The air outlet may be defined in an end wall of the device. The side wall of the device may extend perpendicular to the end wall of the device. The configuration of the air inlet and air outlet may allow air to flow through the heater assembly and thereby entrain the evaporated aerosol-forming substrate. The air outlet may be configured to align with an opening in the barrel. The entrained evaporated aerosol-forming substrate may be aerosolized in the airflow and pass through the air outlet into the barrel.

[0010] The second side of the heater assembly may be located outside of the airflow pathway.The second side of the heater assembly may be configured such that at least a portion of the second side is in contact with the wicking material of the cartridge.

[0011] The heating assembly may be a planar heater assembly. The heating element may be a planar heating element. The heating element may be perpendicular to the longitudinal axis of the device.

[0012] The heating element may comprise at least one wire. The heating element may comprise a plurality of electrically conductive wires. The term "wire" as used herein refers to an electrical path arranged between two electrical contacts. At least one wire may have a cross section that is circular, square, flat or in any other form. The heating element may be an array of wires, for example arranged in parallel with each other. Preferably, the wires may form a mesh.

[0013] The heating element may be a mesh heating element. The heating element may include a mesh. The heating element may allow vapor to flow from the second side of the heater assembly to the first side of the heater assembly. The heating element may not allow liquid to flow from the second side of the heating element to the first side of the heating element.

[0014] The conductive filaments may define interstices between the filaments, and the interstices may have a width of between 10 and 100 microns. Preferably, the filaments create a capillary action in the interstices so that, in use, liquid to be evaporated is drawn into the interstices, increasing the contact area between the heating element and the aerosol-forming substrate.

[0015] The conductive filaments may form a mesh of between 60 and 240 filaments per centimeter (+ / -10%). Preferably, the mesh density is between 100 and 140 filaments per centimeter (+ / -10%). More preferably, the mesh density is about 115 filaments per centimeter. The width of the gaps may be between 100 microns and 25 microns, preferably between 80 microns and 70 microns, more preferably about 74 microns. The percentage of the open area of ​​the mesh as a ratio of the area of ​​the gaps to the total area of ​​the mesh may be between 40% and 90%, preferably between 85% and 80%, more preferably about 82%. The conductive filaments may have a diameter between 8 microns and 100 microns, preferably between 10 microns and 50 microns, more preferably between 12 microns and 25 microns, and most preferably about 16 microns.

[0016] The area of ​​the net of conductive wire can be very small, for example, less than or equal to 50 square millimeters, preferably less than or equal to 25 square millimeters, more preferably about 15 square millimeters. Select size so that heating element is incorporated into handheld system. The size of the net of conductive wire, array or fabric is set to be less than or equal to 50 square millimeters and just reduces the total power required for the net of heating conductive wire, while still ensuring that the net of conductive wire forms sufficient contact with aerosol substrate. The net of conductive wire can be, for example, rectangular, and has a length between 2 millimeters and 10 millimeters, and a width between 2 millimeters and 10 millimeters. Preferably, the net has a size of about 5 millimeters multiplied by 3 millimeters.

[0017] The heating element may comprise a porous material. Advantageously, a mesh heating element, a heating element comprising a mesh or a heating element comprising a porous material may provide a large surface area in contact with the liquid aerosol-forming substrate. This large surface area may provide efficient evaporation of the liquid aerosol-forming substrate.

[0018] Preferably, the heating element comprises a single wire. A heating element comprising a single wire may also be referred to as a heating wire. The single wire may have a diameter of 0.1 mm to 0.5 mm. The single wire may have a diameter of 0.02 mm to 0.2 mm.

[0019] The heating element or portions of the heating element may include a resistive material. The heating element may be configured to resistively heat. In other words, the heating element may be configured to generate heat when an electric current passes through the heating element. The heating element or portions thereof may include or be formed of any material having suitable electrical and mechanical properties (e.g., a suitable resistive material). Suitable materials may include, but are not limited to, semiconductors (e.g., doped ceramics), "conductive" ceramics (e.g., 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 Constantan, nickel-containing alloys, cobalt-containing alloys, chromium-containing alloys, aluminum-containing alloys, titanium-containing alloys, zirconium-containing alloys, hafnium-containing alloys, niobium-containing alloys, molybdenum-containing alloys, tantalum-containing alloys, tungsten-containing alloys, tin-containing alloys, gallium-containing alloys, manganese-containing alloys, and iron-containing alloys, as well as superalloys based on nickel, iron, cobalt, Timetal®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation, 1999 Broadway Suite 4300, Denver Colorado. In the composite material, the resistive material may optionally be embedded in the insulating material, encapsulated by the insulating material, or coated by the insulating material, or vice versa, depending on the kinetics of energy transfer and the desired external physicochemical properties. The heating element or portions thereof may include a metal etched foil isolated between two layers of inert material. In this case, the inert material may include Kapton®, all-polyimide, or mica foil. Kapton® is a registered trademark of EI du Pont de Nemours and Company, 1007 Market Street, Wilmington, Delaware 19898, United States of America.

[0020] Preferably, the heating element comprises stainless steel. Stainless steel can provide the heating element with desirable mechanical properties, corrosion resistance and high electrical resistance.

[0021] The heating element may include a ferrimagnetic material. The heating element may include a ferromagnetic material. The heating element may be formed of a ferrimagnetic material or a ferromagnetic material. At least a portion of the heating element may be formed of a ferrimagnetic material or a ferromagnetic material. The resistance of the heating element may increase as the frequency of the alternating current applied to the heating element increases. Using a heating element including a ferrimagnetic material or a ferromagnetic material may advantageously increase the resistance of the heating element and thus generate more heat locally without reducing the diameter of the heating element. Reducing the diameter may impair the mechanical strength of the heating element.

[0022] The resistance of the heating element may be between 0.1 ohm and 5 ohm. Preferably, the resistance of the heating element may be between 0.4 ohm and 2 ohm.

[0023] The heating element may be coated with a corrosion resistant material. The corrosion resistant coating may increase the life of the heating element. The heating element may be coated with a ceramic material.

[0024] The heater assembly may be configured to contact the wicking portion of the cartridge. The heating element may be configured to contact the wicking portion of the cartridge.

[0025] The heater assembly may include a support element. The support element may provide mechanical support to the heating element. The support element may laterally support the heating element. The support element may include a thermally conductive material in thermal contact with the heating element. The support element may be configured to absorb heat generated by the heating element. Advantageously, the presence of a support element comprising a thermally conductive material may reduce the temperature of the heating element in areas where the heating element is not in contact with the wicking material or the aerosol-forming substrate. This may reduce overheating of the heating element, preferably extending the life of the heating element. Additionally, this may reduce or slow degradation of the wicking material in contact with the heating element.

[0026] The support element may comprise at least one of aluminium, copper, brass, gold, silver or a thermally conductive ceramic. Advantageously, these materials are highly thermally conductive.

[0027] The thermal conductivity of the support element may be at least 10 W / mK. The thermal conductivity of the support element may be at least 50 W / mK. The thermal conductivity of the support element may be at least 200 W / mK.

[0028] The support element may include at least one support pin. The support element may include at least 4, at least 6, at least 8, at least 10 or at least 12 support pins. The heating element may engage with at least one support pin. The heating element may be configured to wrap around or wrap around at least one support pin. The heating element may be a heating wire, wherein the heating wire passes around each of the support pins.

[0029] At least one support pin may be cylindrical.The cross section of at least one support pin may have a diameter of 0.5 mm to 5 mm, preferably 1 mm to 2 mm.

[0030] The heater assembly may further comprise a heater holder. The heater holder may provide mechanical support to the support element. The heater holder may comprise an upper plate and a lower plate. The heating element may be located between the upper plate and the lower plate. Advantageously, the heater holder comprising the upper plate and the lower plate between which the heating element is located may be directly manufactured.

[0031] The heater holder may have an orifice defined therethrough. The orifice may be defined through the upper plate and the lower plate. The heating element may span at least a portion of the orifice. The orifice may be configured to allow an aerosol-forming substrate to flow between the second side of the heater assembly and the first side of the heater assembly. The orifice may be configured to allow a gas (e.g., air and vapor generated by the aerosol-forming substrate) to flow between the second side of the heater assembly and the first side of the heater assembly.

[0032] The aerosol generating device may also include a first electrical connector and a second electrical connector. The first electrical connector and the second electrical connector may be configured to supply power to the heating element. The electrical connector may be in electrical contact with the heating element. The first electrical connector may include a first contact pad, and the second electrical connector may include a second electrical contact pad, wherein the first electrical contact pad and the second electrical contact pad are configured to be in electrical contact with the heating element. The electrical connector may extend outside the heater assembly to allow electrical energy to be provided from a power source to the electrical connector and therefore to the heating element. In operation, the heating element may be heated due to the passage of current through the heating element. The first electrical connector and the second electrical connector may be located on opposite sides of the heating element. The current transferred from the first electrical connector to the second electrical connector may pass through the heating element.

[0033] The support element can be positioned adjacent to the orifice. The support element can be positioned as close to the orifice as possible. The distance between the support element and the orifice can be less than 2 mm, preferably less than 1 mm. Advantageously, this can minimize the total length of the heating element. The length of the heating element that does not cross the orifice can also be reduced. The percentage of the heating element that crosses the orifice can be increased. Increasing the percentage of the heating element that crosses the orifice can increase the percentage of the second side of the heating element that is configured to contact the cylinder to receive the aerosol-forming substrate. Advantageously, the manufacturing of the heating element may require less material without reducing the performance of the heating element. The electrical connector can be in electrical contact with the heating element when the distance from the orifice is farther than the distance from the support element to the orifice. The first electrical connector can be in electrical contact with the first end of the heating element. The second electrical connector can be in contact with the second end of the heating element. The electrical connector can be connected in series with the heating element. Preferably, the heating element can have a diameter of 0.1 mm to 0.5 mm.

[0034] The first electrical connector and the second electrical connector may be positioned adjacent to the orifice. The support element may contact the heating element at a distance from the orifice that is farther than the distance between the first electrical connector and the second electrical connector and the orifice. The first electrical connector and the second electrical connector may be positioned as close to the orifice as possible. The distance between the first electrical connector and the orifice may be less than 2 mm, preferably less than 1 mm. The distance between the second electrical connector and the orifice may be less than 2 mm, preferably less than 1 mm. In this configuration, the length of the heating element between the first electrical connector and the second electrical connector is shorter than in the previous configuration. Therefore, a small diameter of the heating element is selected. The first electrical connector and the second electrical connector, preferably the first electrical contact pad and the second electrical contact pad, may be configured to absorb some of the heat generated by the heating element in operation. Advantageously, this may reduce the temperature of a portion of the heating element that is not in contact with the aerosol-forming substrate or is configured to be in contact with the aerosol-forming substrate. The first electrical connector and the second electrical connector, preferably the first electrical contact pad and the second electrical contact pad, may contact the heating element at more than two positions on the heating element. The first electrical connector and the second electrical connector, preferably the first electrical contact pad and the second electrical contact pad, may be connected in parallel with the heating element. Preferably, the heating element may have a diameter of 0.02 mm to 0.2 mm.

[0035] The cross-sectional area of ​​the orifice may be from 4 square millimeters to 1000 square millimeters. Preferably, the cross-sectional area of ​​the orifice may be from 9 square millimeters to 400 square millimeters. Most preferably, the cross-sectional area of ​​the orifice may be from 16 square millimeters to 100 square millimeters. Any shape may be selected for the cross section of the orifice. Preferably, the cross section of the orifice may be circular, square or rectangular. Advantageously, these cross-sectional shapes of the orifice may be easy to manufacture.

[0036] The heater holder may be electrically insulating. The heater holder may have a thermal conductivity of 1 W / mK or less. The heater holder may include a heat resistant polymer. The heater holder may include polyetheretherketone (PEEK). The heater holder may include a liquid crystal polymer (LCP). The heater holder may include ceramic. The heater holder may include alumina. The heater holder may include zirconium oxide. Advantageously, these materials are able to withstand high temperatures.

[0037] The heating element may be or may include a susceptor material. The susceptor material may be configured to be inductively heated. In operation, the susceptor material may be heated by eddy currents induced in the susceptor material. Hysteresis losses may also contribute to inductive heating.

[0038] The device may not include a wicking element. After repeated heating of the aerosol-forming substrate in an aerosol generating system, the wicking element may degrade faster than other components such as the heating element. Degraded wicking material may need to be replaced before other components of the system such as the heater assembly. Therefore, a device without a wicking element may increase the life of the device.

[0039] The heater assembly may comprise a compressible element.The compressible element may be configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0040] The compressible element may be a spring. The spring may be positioned adjacent to or in contact with the lower plate of the heater holder. The compressible element may allow the heater assembly to move along the longitudinal axis of the device. In use, when the cartridge is attached to the device, the cartridge may provide a force to the heater assembly to move the heater assembly. When the cartridge is coupled to the device, the spring may be compressed. When the cartridge is separated from the device, the spring may expand. The spring may be positioned to resist the force provided by inserting the cartridge. Advantageously, a tight fit between the cartridge and the heater assembly may be achieved to reduce the likelihood of leakage of the aerosol-forming substrate. The tight fit may provide a more efficient heating of the aerosol-forming substrate.

[0041] The aerosol generating device may further comprise a power source. The power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery or a lithium polymer battery. The battery may be a nickel metal hydride battery or a nickel cadmium battery. The power source may be another form of charge storage device, such as a capacitor. The power source may be configured to supply power to the heating element. This may heat the heating element.

[0042] The power supply may be configured to supply alternating current. The power supply may include a direct current-alternating current (DC / AC) inverter for converting a DC current provided by the DC power supply into an alternating current.

[0043] The power supply may be configured to supply power to the heating element to resistively heat the heating element.The power supply may be configured to supply power to the heating element to inductively heat the heating element.

[0044] The power supply may be electrically connected to the first electrical connector and the second electrical connector. The power supply may be configured to supply power to the heating element via the electrical connector. The power supply may be configured to supply power to the heating element by passing an electric current through the heating element.

[0045] The aerosol generating device may further comprise a control circuit. The control circuit may comprise a controller. The controller may be a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated chip (ASIC) or other electronic control circuit. The controller may be configured to control the supply of power from the power supply. The controller may be configured to regulate the supply of power from the power supply to the heater assembly. Thus, the controller may control the heating of the heating element.

[0046] The heating element may be airflow actuated. The heating element may be puff actuated. The aerosol generating device may include a puff detector. The puff detector may communicate with the control circuit. The puff detector may be configured to detect when there is airflow through the airflow path. The control circuit may be configured to activate the heating element when airflow is detected.

[0047] The aerosol generating device may be a handheld aerosol generating device.

[0048] It would be desirable to provide a heater assembly in which the likelihood of hot spots occurring is reduced compared to prior art systems.

[0049] According to a second aspect of the present disclosure, a heater assembly for an aerosol generating device is provided, the heater assembly may include: a heater holder including an orifice, a heating element spanning at least a portion of the orifice, a first electrical connector and a second electrical connector electrically contacting the heating element, and a support element, the support element including a heat conductive material in thermal contact with the heating element. The heater assembly of the second aspect may include any features of the heater assembly described with respect to the first aspect of the present disclosure. In addition, any features of the heater assembly of the second aspect may also be applied to the heater assembly of the first aspect.

[0050] Advantageously, the support element comprising a thermally conductive material conducts heat away from the hot spots of the heating element. Thus, a more consistent temperature is produced along the heating element. This can reduce degradation of the wicking material adjacent to or in contact with the heating element during use of the heater assembly.

[0051] The heating assembly may be a planar heater assembly. The heating element may be a planar heating element. The heating element may be a mesh heating element. The heating element may include a mesh. The heating element may include a porous material. Advantageously, a mesh heating element, a heating element including a mesh, or a heating element including a porous material may provide a large surface area in contact with the liquid aerosol-forming substrate. This large surface area may provide efficient evaporation of the liquid aerosol-forming substrate.

[0052] The heating element may comprise at least one wire. The heating element may comprise a plurality of electrically conductive wires. The term "wire" as used herein refers to an electrical path arranged between two electrical contacts. At least one wire may have a cross-section of a circular, square, flat or any other form. Preferably, the heating element comprises a single wire. A heating element comprising a single wire may also be referred to as a heating wire. The heating element may have a diameter of 0.1 mm to 0.5 mm. The heating element may have a diameter of 0.02 mm to 0.2 mm.

[0053] The heating element or portions of the heating element may include a resistive material. The heating element may be configured for resistive heating. The heating element or portions thereof may include or be formed of any material having suitable electrical and mechanical properties (e.g., a suitable resistive material).

[0054] The heating element may comprise stainless steel. Stainless steel may provide the heating element with desirable mechanical properties, corrosion resistance and high electrical resistance.

[0055] The heating element may include a ferrimagnetic material. The heating element may include a ferromagnetic material. The heating element may be formed of a ferrimagnetic material or a ferromagnetic material. At least a portion of the heating element may be formed of a ferrimagnetic material or a ferromagnetic material. The resistance of the heating element may increase as the frequency of the alternating current applied to the heating element increases. Using a heating element including a ferrimagnetic material or a ferromagnetic material may advantageously increase the resistance of the heating element and thus generate more heat locally without reducing the diameter of the heating element. Reducing the diameter may impair the mechanical strength of the heating element.

[0056] The total resistance of the heating element may be from 0.1 ohm to 5 ohm, preferably from 0.4 ohm to 2 ohm. Advantageously, a resistance within this range allows the heating element to reach a temperature suitable for evaporation of the aerosol-forming substrate.

[0057] The heating element may be coated with a corrosion resistant material. The corrosion resistant coating may increase the life of the heating element. The heating element may be coated with a ceramic material.

[0058] The support element may be configured to absorb the heat generated by the heating element. The support element may provide mechanical support to the heating element. The support element may laterally support the heating element. The support element may include a heat conductive material in thermal contact with the heating element. The support element may be configured to absorb the heat generated by the heating element. Advantageously, the presence of a support element comprising a heat conductive material can reduce the temperature of the heating element in areas where the heating element is not in contact with the wicking material or the aerosol-forming substrate. This can reduce overheating of the heating element, preferably extending the life of the heating element. In addition, this can reduce or slow down the degradation of the wicking material in contact with the heating element. Advantageously, the support element conducts heat away from the hot spots of the heating element, thereby producing a more consistent temperature along the heating element. This can reduce the degradation of the wicking material adjacent to or in contact with the heating element during use of the heater assembly.

[0059] The support element may comprise at least one of aluminium, copper, brass, gold, silver or a thermally conductive ceramic. Advantageously, these materials are highly thermally conductive.

[0060] The thermal conductivity of the support element may be at least 10 W / mK. Preferably, the thermal conductivity of the support element may be at least 50 W / mK. Preferably, the thermal conductivity of the support element may be at least 200 W / mK.

[0061] The support element may include at least one support pin. The heating element may engage with at least one support pin. The support element may include at least 4, at least 6, at least 8, at least 10 or at least 12 support pins. The heating element may engage with at least one support pin. The heating element may be configured to wrap or wrap around at least one support pin. The heating element may be a single wire, wherein the wire passes around each of the support pins.

[0062] At least one support pin may be cylindrical.At least one support pin may have a diameter of 0.5 mm to 5 mm, preferably 1 mm to 2 mm.

[0063] The heater holder may provide mechanical support to the support element. The heater holder may comprise an upper plate and a lower plate. The heating element may be located between the upper plate and the lower plate. Advantageously, the heater holder comprising an upper plate and a lower plate between which the heating element is located may be manufactured directly. The support element may be attached to the heater holder. The support element may be mechanically fixed to the heater holder. The support element may be pressed into the heater holder. The support element may be fixed to the heater holder with an adhesive such as glue. The support element may be mechanically fixed to the lower plate. The support element may be mechanically fixed to the upper plate. There may be an interference fit between the support element and the heater holder.

[0064] The upper plate may be mechanically fixed to the lower plate. The upper plate may be fixed to the lower plate with fasteners. Suitable fasteners may be screws or rivets. The upper plate may be fixed to the lower plate with an adhesive. The upper plate may be fixed to the lower plate by plastic welding of the upper and lower plates. The upper plate may be fixed to the lower plate by overmolding.

[0065] The heater holder may have an orifice defined therethrough. The orifice may be defined through the upper plate and the lower plate. The heating element may span at least a portion of the orifice. The orifice may be configured to allow an aerosol-forming substrate to flow between the second side of the heater assembly and the first side of the heater assembly. The orifice may be configured to allow a gas (e.g., air and vapor generated by the aerosol-forming substrate) to flow between the second side of the heater assembly and the first side of the heater assembly.

[0066] The first electrical connector and the second electrical connector may be configured to supply power to the heating element. The electrical connector may be in electrical contact with the heating element. The first electrical connector may include a first contact pad, and the second electrical connector may include a second electrical contact pad, wherein the first electrical contact pad and the second electrical contact pad are configured to be in electrical contact with the heating element. The electrical connector may extend outside the heater assembly to allow electrical energy to be provided from a power source to the electrical connector and thus to the heating element. In operation, the heating element may be heated due to the passage of current through the heating element. The first electrical connector and the second electrical connector may be located on opposite sides of the heating element. The current transferred from the first electrical connector to the second electrical connector may pass through the heating element.

[0067] The support element can be positioned adjacent to the orifice. The support element can be positioned as close to the orifice as possible. The distance between the support element and the orifice can be less than 2 mm, preferably less than 1 mm. Advantageously, this can minimize the total length of the heating element. The length of the heating element that does not cross the orifice can also be reduced. The percentage of the heating element that crosses the orifice can be increased. Increasing the percentage of the heating element that crosses the orifice can increase the percentage of the second side of the heating element that is configured to contact the cylinder to receive the aerosol-forming substrate. Advantageously, less material may be required to manufacture the heating element without reducing the performance of the heating element. Hot spots in the heating element are more likely to occur at the portion of the heating element that contacts the heater holder. Therefore, the support element can be positioned adjacent to the orifice where the heating element will contact the heater holder. This can reduce the occurrence of hot spots in the heating element during use of the heater assembly.

[0068] The electrical connector may be in electrical contact with the heating element at a distance from the orifice that is further than the distance of the support element from the orifice. The first electrical connector may be in electrical contact with a first end of the heating element. The second electrical connector may be in contact with a second end of the heating element. The electrical connector may be connected in series with the heating element. Preferably, the heating element may have a diameter of 0.1 mm to 0.5 mm.

[0069] The first electrical connector and the second electrical connector may be positioned adjacent to the orifice. The support element may contact the heating element at a distance from the orifice that is farther than the distance between the first electrical connector and the second electrical connector and the orifice. The first electrical connector and the second electrical connector may be positioned as close to the orifice as possible. The distance between the first electrical connector and the orifice may be less than 2 mm, preferably less than 1 mm. The distance between the second electrical connector and the orifice may be less than 2 mm, preferably less than 1 mm. In this configuration, the length of the heating element between the first electrical connector and the second electrical connector is shorter than in the previous configuration. Therefore, a small diameter of the heating element is selected. The first electrical connector and the second electrical connector, preferably the first electrical contact pad and the second electrical contact pad, may be configured to absorb some of the heat generated by the heating element in operation. Advantageously, this may reduce the temperature of a portion of the heating element that is not in contact with the aerosol-forming substrate or is configured to be in contact with the aerosol-forming substrate. The first electrical connector and the second electrical connector, preferably the first electrical contact pad and the second electrical contact pad, may contact the heating element at more than two positions on the heating element. The first electrical connector and the second electrical connector, preferably the first electrical contact pad and the second electrical contact pad, may be connected in parallel with the heating element. Preferably, the heating element may have a diameter of 0.02 mm to 0.2 mm.

[0070] The cross-sectional area of ​​the orifice may be from 4 square millimeters to 1000 square millimeters. Preferably, the cross-sectional area of ​​the orifice may be from 9 square millimeters to 400 square millimeters. Most preferably, the cross-sectional area of ​​the orifice may be from 16 square millimeters to 100 square millimeters. Any shape may be selected for the cross section of the orifice. Preferably, the cross section of the orifice may be circular, square or rectangular. Advantageously, these cross-sectional shapes of the orifice may be easy to manufacture.

[0071] The heater holder may be electrically insulating. The heater holder may be thermally insulating. The heater holder may have a thermal conductivity of 1 W / mK or less. The heater holder may include a heat resistant polymer. The heater holder may include polyetheretherketone (PEEK). The heater holder may include a liquid crystal polymer (LCP). The heater holder may include a ceramic. The heater holder may include alumina. The heater holder may include zirconium oxide. Advantageously, these materials are able to withstand high temperatures, preferably higher temperatures than may be reached during normal operation of the heating element.

[0072] The heater assembly may comprise a compressible element.The compressible element may be configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0073] The compressible element may be a compressible wicking element.The compressible wicking element may be located on the second side of the heater assembly.

[0074] The compressible element may be a spring. The spring may be positioned adjacent to or in contact with the lower plate of the heater holder. The compressible element may allow the heater assembly to move along the longitudinal axis of the device. In use, when the cartridge is attached to the device, the cartridge may provide a force to the heater assembly to move the heater assembly. When the cartridge is coupled to the device, the spring may be compressed. When the cartridge is separated from the device, the spring may expand. The spring may be positioned to resist the force provided by inserting the cartridge. Advantageously, a tight fit between the cartridge and the heater assembly may be achieved to reduce the likelihood of leakage of the aerosol-forming substrate. The tight fit may provide a more efficient heating of the aerosol-forming substrate.

[0075] According to a third aspect of the present disclosure, there is provided a cartridge configured to be coupled to an aerosol generating device as described in the first aspect of the present disclosure. The cartridge may include an aerosol-forming substrate and a wicking material in fluid communication with the aerosol-forming substrate. The wicking material may form a portion of an outer surface of the cartridge and may be configured to contact the aerosol generating device.

[0076] The cartridge may not include a heater assembly. The cartridge may not include a heating element. Advantageously, the cost and complexity of manufacturing the cartridge may be reduced compared to cartridges of the prior art, such as cartridges comprising a wicking material and a heating element in contact with the wicking material. The cartridge may be disposed of when the wicking material typically becomes degraded after multiple heating cycles. Advantageously, the cartridge may be separated from the aerosol generating device and the cartridge disposed of. The aerosol generating device and the components contained therein may be reused.

[0077] The cylinder may include a cylinder air flow path defined between a cylinder air inlet and a cylinder air outlet. When negative pressure is applied to the cylinder air outlet, air is drawn into the cylinder air inlet and forms an air flow from the cylinder air inlet to the cylinder air outlet in the air flow path.

[0078] The cartridge may include a mouthpiece. The mouthpiece may be a removable mouthpiece. The mouthpiece may include a cartridge air outlet. In use, when the cartridge is engaged with the aerosol generating device, a user may draw on the mouthpiece of the cartridge.

[0079] The aerosol-forming substrate may be a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be solid or liquid, or include both solid and liquid components. The aerosol-forming substrate may be a fluid. The aerosol-forming substrate may be a gel. The gel may be solid at room temperature. "Solid" in this context means that the gel has a stable size and shape and does not flow. In this context, room temperature means 25 degrees Celsius. Preferably, the aerosol-forming substrate is a liquid.

[0080] The aerosol-forming substrate may include plant-based materials. The aerosol-forming substrate may include tobacco. The aerosol-forming substrate may include tobacco-containing materials containing volatile tobacco flavor compounds, which are released from the aerosol-forming substrate when heated. The aerosol-forming substrate may include non-tobacco-containing materials.

[0081] The aerosol-forming matrix may include at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that promotes the formation of a dense and stable aerosol in use and is substantially resistant to thermal degradation at the operating temperature of the system. Suitable aerosol formers are well known in the art and include, but are not limited to: polyols, such as triethylene glycol, 1,3-butylene glycol and glycerol; esters of polyols, such as glycerol mono-, di- or triacetate; and fatty acid esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanoic acid. Preferred aerosol formers are polyols or mixtures thereof, such as triethylene glycol, 1,3-butylene glycol and most preferably glycerol. The aerosol-forming matrix may include other additives and ingredients, such as fragrances.

[0082] The cartridge may comprise a reservoir for containing the aerosol-forming substrate. The reservoir may have a shape of any size suitable for containing the aerosol-forming substrate within the cartridge. The wicking material may be in fluid communication with the aerosol-forming substrate contained in the reservoir.

[0083] The reservoir may include at least one opening. At least one opening may be in contact with the wicking material. The wicking material may be in fluid communication with the reservoir via at least one opening. At least one opening may be configured to allow an aerosol-forming substrate to flow from the reservoir to the wicking material. At least one opening may be configured to allow one or more gases to flow from the wicking material to the reservoir. During use of the cartridge, an aerosol-forming substrate may flow from the reservoir to the wicking material, and a gas such as air may flow to the reservoir through the wicking material. This may allow pressure to balance within the cartridge.

[0084] The cartridge may comprise a wicking portion. The wicking portion may comprise a wicking material. The wicking material may form part of an outer surface of the cartridge and may be configured to contact a heating element of the aerosol generating device.

[0085] The wicking material may include or may be a material impregnated with an aerosol-forming substrate, or may be configured to be impregnated with an aerosol-forming substrate. The wicking material may have a fibrous or spongy structure. The wicking material may be a capillary material. A capillary material is a material that actively transports a liquid from one end of the material to the other end. The capillary material may have a fibrous or spongy structure. The capillary material preferably includes a capillary bundle. For example, the capillary material may include a plurality of fibers or threads or other fine-pore tubes. The fibers or threads may be substantially aligned to convey the aerosol-forming substrate. Alternatively, the capillary material may include a spongy or foamy material. The structure of the capillary material forms a plurality of pores or tubes through which the aerosol-forming substrate may be transported by capillary action. The capillary material may include any suitable material or combination of materials. Examples of suitable materials are sponges or foams, ceramic or graphite-based materials in the form of fibers or sintered powders, foamed metals or plastic materials, for example fibrous materials made from spun or extruded fibers, such as cellulose acetate, polyester or bonded polyolefins, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics. The capillary material may have any suitable capillarity and porosity for use with different aerosol-forming substrate physical properties. The aerosol-forming substrate has physical properties, including but not limited to viscosity, surface tension, density, thermal conductivity, boiling point and vapor pressure, which allow the aerosol-forming substrate to be transported through the capillary material by capillary action.

[0086] Preferably, the wicking material may be a ceramic wick. The ceramic wick may comprise or preferably consist of a ceramic material. Preferably, when the wicking element is a ceramic wick, the wicking element may comprise a porous ceramic. The porous ceramic wick may comprise an open-pore ceramic. The ceramic wick may be rigid. The ceramic wick may not deform when the cartridge is coupled to the aerosol generating device.

[0087] The cartridge may also include a compressible element. The cartridge compressible element may be a compressible wicking element. The compressible wicking element may be a wicking material. The compressible wicking element may be positioned adjacent to the wicking material.

[0088] The compressible wicking element may comprise a compressible material or preferably consist of a compressible material. For example, the compressible wicking element preferably comprises a sponge or foam material. The compressible wicking element may form a part of the device connection portion and is configured to contact the aerosol generating device. When the tube is connected to the aerosol generating device, the compressible wicking element may be compressed. This can advantageously ensure that the contact area between the compressible wicking element and the device is maximized, and thus improve the delivery of the aerosol-forming substrate to the heating element, thereby improving the heating efficiency. Preferably, the compressible wicking element may comprise an elastic material or consist of an elastic material. Such a wicking element can advantageously return to its original shape after being compressed. Therefore, when the tube is separated from the aerosol generating device, the compressible wicking element can return to its original shape.

[0089] The wicking material may have any suitable cross-sectional shape. The wicking material may have a square, rectangular or circular cross-section. Wicking materials of this shape may be easy to manufacture. Preferably, the wicking material is cylindrical.

[0090] The wicking material may have a width between 2 mm and 32 mm, preferably between 3 mm and 20 mm, more preferably between 4 mm and 10 mm. If the wicking element is cylindrical, the value of the width corresponds to the value of the diameter of the cylindrical wicking element.

[0091] The barrel may include a device coupling portion. The device coupling portion may be configured to couple to an aerosol generating device. The device coupling portion may include a barrel air inlet. The device coupling portion may be disposed on an end of the barrel opposite to the barrel air outlet. The device coupling portion may include a wicking material. The wicking material may protrude from the surface of the device coupling portion. This may allow the wicking material to easily contact the barrel coupling portion of the device. In particular, this may allow the wicking material to easily contact the heating element of the device. The wicking material may protrude from the surface of the device coupling portion by at least 1 mm, preferably by at least 2 mm, more preferably by at least 3 mm.

[0092] The tube may also include a removable seal. The removable seal may be configured to cover the wicking material before using the tube. Advantageously, the removable seal may protect the wicking material from damage or contamination before using the tube. The removable seal may also prevent the wicking material and thus the aerosol-forming substrate from being exposed to air before using the tube. Advantageously, the removable seal may reduce the evaporation of the aerosol-forming substrate from the wicking material before the tube is connected to the aerosol generating device. The removable seal may advantageously prevent the aerosol-forming substrate from being lost or leaking from the tube before using the tube, particularly during storage or transportation. The removable seal may be configured to be removed by a user before using the tube. The removable seal may be configured to be removed by a user before the tube is connected to the aerosol generating device.

[0093] The barrel may further comprise a protruding wall. The protruding wall may protrude from the surface of the device coupling portion. The protruding wall may protrude from the surface of the device coupling portion by at least 1 mm, preferably by at least 2 mm, more preferably by at least 3 mm. The protruding wall may surround the periphery of the device coupling portion. The protruding wall may be configured to contact or be received by the aerosol generating device. The protruding wall may be configured to contact or be received by the barrel coupling portion of the aerosol generating device.

[0094] The protruding wall may be configured to protrude from the surface of the device coupling portion by at least the same amount as the wicking material. The protruding wall may be configured to protrude from the surface of the device coupling portion more than the wicking material. Advantageously, the protruding wall may protect the wicking material from impact or damage. The protruding wall may be configured to engage with the aerosol generating device. A removable seal may be attached to the protruding wall. The removable seal may be attached to the protruding wall by an adhesive. The removable seal may not be in contact with the wicking material.

[0095] The cartridge air inlet may include a partition wall protruding from the surface of the device coupling portion. The partition wall may protrude at least 1 mm, preferably at least 2 mm, more preferably at least 3 mm from the surface of the device coupling portion. The partition wall may protrude from the surface of the device coupling portion by at least the same amount as the wicking material. The partition wall may protrude from the surface of the device coupling portion by more than the wicking material. The partition wall may protrude from the surface of the device coupling portion less than the protruding wall. The partition wall may protrude from the surface of the device coupling portion by the same amount as the protruding wall. A removable seal may cover the cartridge air inlet. Advantageously, this may protect the cartridge air inlet from contaminants before the user removes the removable seal, particularly during storage and transportation of the cartridge. The partition wall may be configured to engage with the aerosol generating device.

[0096] It would be desirable to provide an aerosol generating system which has reduced degradation of the wicking material and requires less frequent disposal of the cartridge and heater assembly than prior art systems.

[0097] According to a fourth aspect of the present disclosure, there is provided an aerosol generating system.The aerosol generating system may comprise any of the features of the aerosol generating device, heater assembly or cartridge described in relation to the first, second or third aspect of the present disclosure.

[0098] The aerosol generating system may include a tube. The tube may include an aerosol-forming substrate in fluid communication with a wicking material, wherein the wicking material forms a portion of the outer surface of the tube. The aerosol generating system may also include an aerosol generating device. The aerosol generating device may include a tube coupling portion for engaging a tube including an aerosol-forming substrate, an air flow path defined between an air inlet of the device and an air outlet of the device, and a heater assembly. The heater assembly may include a fluid-permeable heating element configured to heat an aerosol-forming substrate from the tube. The heater assembly may include a first side and a second side, the first side being opposite to the second side, wherein the first side forms at least a portion of a surface of a wall of the air flow path, and wherein the second side forms a portion of the tube coupling portion, and is configured to contact the wicking material of the tube to receive the aerosol-forming substrate.

[0099] Advantageously, when the cartridge needs to be replaced, the heater assembly can remain in the device, rather than being removed and disposed of. The heater assembly may be more expensive to manufacture than other elements of the cartridge, so preventing unnecessary disposal of the heater assembly may be advantageous. Placing the heater assembly in the device may mean that the cartridge does not include the heater assembly. Therefore, the cartridge may be less expensive and simpler to manufacture than a cartridge that includes a heater assembly.

[0100] The aerosol-forming substrate may be a substrate capable of releasing volatile compounds that may form an aerosol. The volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be solid or liquid, or include both solid and liquid components. The aerosol-forming substrate may be a fluid. The aerosol-forming substrate may be a gel. The gel may be solid at room temperature. "Solid" in this context means that the gel has a stable size and shape and does not flow. In this context, room temperature means 20 degrees Celsius. Preferably, the aerosol-forming substrate is a liquid.

[0101] The cartridge may comprise a reservoir for containing the aerosol-forming substrate. The reservoir may have a shape of any size suitable for containing the aerosol-forming substrate within the cartridge. The wicking material may be in fluid communication with the aerosol-forming substrate contained in the reservoir.

[0102] The reservoir may include at least one opening. At least one opening may be in contact with the wicking material. The wicking material may be in fluid communication with the reservoir via at least one opening. At least one opening may be configured to allow an aerosol-forming substrate to flow from the reservoir to the wicking material. At least one opening may be configured to allow one or more gases to flow from the wicking material to the reservoir. During use of the cartridge, an aerosol-forming substrate may flow from the reservoir to the wicking material, and a gas such as air may flow to the reservoir through the wicking material. This may allow pressure to balance within the cartridge.

[0103] The cartridge may comprise a wicking portion. The wicking portion may comprise a wicking material. The wicking material may form part of an outer surface of the cartridge and may be configured to contact a heating element of the aerosol generating device.

[0104] The wicking material may include or may be a material impregnated with an aerosol-forming substrate, or a material configured to be impregnated with an aerosol-forming substrate. The wicking material may have a fibrous or sponge-like structure. The wicking material may be a capillary material.

[0105] The wicking material may be a ceramic wick. The ceramic wick may comprise or preferably consist of a ceramic material. Preferably, when the wicking element is a ceramic wick, the wicking element may comprise a porous ceramic. The porous ceramic wick may comprise an open-pore ceramic. The ceramic wick may be rigid. The ceramic wick may not deform when the cartridge is coupled to the aerosol generating device.

[0106] The cartridge may comprise a cartridge air inlet and a cartridge air outlet, wherein the cartridge air inlet is aligned with the device air outlet. The cartridge air outlet may comprise a mouthpiece.

[0107] The device air inlet may be defined in a side wall of the aerosol generating device. The device air outlet may be defined in an end wall of the aerosol generating device. The side wall of the aerosol generating device may extend perpendicularly to the end wall of the aerosol generating device. The device air outlet may be configured to align with an opening in the barrel.

[0108] When the cartridge is coupled to the device, an airflow path may be formed from the device air inlet to the cartridge air outlet. During use of the aerosol generating system, the user may suck on the cartridge air outlet. This may draw air into the device air inlet, through the heating element, through the device air outlet, through the cartridge air inlet and out of the cartridge air outlet to the user.

[0109] The second side of the heater assembly may be located outside the airflow path. The second side of the heater assembly may be configured to contact the wicking material of the cartridge. The heater assembly may be a planar heater assembly.

[0110] The heater assembly may include a heater holder. The heater holder may have an orifice defined therethrough. The heater holder may include an upper plate and a lower plate. The orifice may be defined through the upper plate and the lower plate. The heating element may span at least a portion of the orifice. The orifice may be configured to allow an aerosol-forming substrate to flow between a second side of the heater assembly and a first side of the heater assembly. The orifice may be configured to allow a gas (e.g., air and vapor generated by the aerosol-forming substrate) to flow between the second side of the heater assembly and the first side of the heater assembly.

[0111] The shape that the wicking material has may correspond to the shape of the orifice of the heater assembly. The cross-sectional area that the wicking material has may correspond to the cross-sectional area of ​​the orifice of the heater assembly for the aerosol generating device. The cross-sectional area of ​​the wicking material corresponding to the cross-sectional area of ​​the orifice of the heater assembly may advantageously allow good contact between the wicking material and the heating element of the heater assembly. The cross-sectional area that the wicking material has may be at least 2%, 3%, 4% or 5% smaller than the cross-sectional area of ​​the orifice of the heater assembly for the aerosol generating device. This may allow the wicking material to be easily received by the orifice of the heater assembly. The wicking material may have any suitable cross-sectional shape. The wicking material may have a square, rectangular or circular cross-section. The wicking material of this shape may be easy to manufacture. Preferably, the wicking material is cylindrical.

[0112] The wicking material may have a width between 2 mm and 32 mm, preferably between 3 mm and 20 mm, more preferably between 4 mm and 10 mm. If the wicking element is cylindrical, the value of the width corresponds to the value of the diameter of the cylindrical wicking element.

[0113] The heater assembly may be configured to contact the wicking portion of the cartridge. The heating element may be configured to contact the wicking portion of the cartridge.

[0114] The heating element may be a mesh heating element. The heating element may include a mesh. The heating element may include a porous material. Advantageously, a mesh heating element, a heating element comprising a mesh, or a heating element comprising a porous material may provide a large surface area in contact with the liquid aerosol-forming substrate. This large surface area may provide efficient evaporation of the liquid aerosol-forming substrate.

[0115] The heating element may comprise at least one wire. The heating element may comprise a plurality of electrically conductive wires. The term "wire" as used herein refers to an electrical path arranged between two electrical contacts. At least one wire may have a cross-section of a circular, square, flat or any other form. Preferably, the heating element comprises a single wire. A heating element comprising a single wire may also be referred to as a heating wire. The heating element may have a diameter of 0.1 mm to 0.5 mm. The heating element may have a diameter of 0.02 mm to 0.2 mm.

[0116] The heating element or portions of the heating element may include a resistive material. The heating element may be configured to resistively heat. In other words, the heating element may be configured to generate heat when an electric current passes through the heating element.

[0117] Preferably, the heating element comprises stainless steel. Stainless steel can provide the heating element with desirable mechanical properties, corrosion resistance and high electrical resistance.

[0118] The heater assembly may include a support element. The support element may provide mechanical support to the heating element. The support element may laterally support the heating element. The support element may include a heat conductive material in thermal contact with the heating element. The support element may be configured to absorb heat generated by the heating element. The support element comprising a heat conductive material may conduct heat away from the heating element at the area where the heating element contacts the support element. Advantageously, the presence of a support element comprising a heat conductive material may reduce the temperature of the heating element in areas where the heating element is not in contact with the wicking material or the aerosol-forming substrate. This may reduce overheating of the heating element, preferably extending the life of the heating element. In addition, this may reduce or slow down the degradation of the wicking material in contact with the heating element. Advantageously, a support element comprising a heat conductive material may reduce the likelihood of forming hot spots in the heating element. Reducing hot spots may increase the life of the heating element. Reducing hot spots may also increase the life of the wicking material of the cartridge.

[0119] The heater assembly may comprise a compressible element.The compressible element may be configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0120] The compressible element may be a spring.

[0121] The compressible element may be a compressible wicking element.

[0122] The cartridge may include a cartridge housing. The device may include a device housing. The cartridge housing and the device housing may be rigid. The cartridge housing may engage with the device housing. When the device housing engages with the cartridge housing, the compressible element may be compressed.

[0123] The aerosol generating system may further include a first electrical connector and a second electrical connector. The first electrical connector and the second electrical connector may be configured to supply power to the heating element. The electrical connector may be in electrical contact with the heating element. The first electrical connector may include a first contact pad, and the second electrical connector may include a second electrical contact pad, wherein the first electrical contact pad and the second electrical contact pad are configured to be in electrical contact with the heating element. The electrical connector may extend outside the heater assembly to allow electrical energy to be provided from a power source to the electrical connector and thus to the heating element. In operation, the heating element may be heated due to the passage of electric current through the heating element. The first electrical connector and the second electrical connector may be located on opposite sides of the heating element. The electric current transferred from the first electrical connector to the second electrical connector may pass through the heating element.

[0124] The aerosol generating system may further comprise a power source. The power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery. The battery may be a nickel metal hydride battery or a nickel cadmium battery. The power source may be another form of charge storage device, such as a capacitor. The power source may be configured to supply power to the heating element. This may heat the heating element.

[0125] The power supply may be configured to supply power to the heating element to resistively heat the heating element.

[0126] The power supply may be electrically connected to the first electrical connector and the second electrical connector. The power supply may be configured to supply power to the heating element via the electrical connector. The power supply may be configured to supply power to the heating element by passing an electric current through the heating element.

[0127] The aerosol generating system may further comprise a control circuit. The control circuit may comprise a controller. The controller may be a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated chip (ASIC) or other electronic control circuit. The controller may be configured to control the power supply from the power supply. The controller may be configured to regulate the power supply from the power supply to the heater assembly. Thus, the controller may control the heating of the heating element.

[0128] The aerosol generating system may be puff-activated. The heating element may be airflow-activated. The heating element may be puff-activated. The aerosol generating system may include a puff detector. The puff detector may communicate with the control circuit. The puff detector may be configured to detect when there is airflow through the airflow path. The control circuit may be configured to activate the heating element when airflow is detected.

[0129] The aerosol generating system may be a handheld aerosol generating system. The aerosol generating system may have a size comparable to a conventional cigar or cigarette. The aerosol generating system may have an overall length between about 30 mm and about 150 mm. The aerosol generating system may have an outer diameter between about 5 mm and about 30 mm.

[0130] As used herein, the term "heating element" refers to an element of a heater assembly that is configured to be heated. For example, the term "heating element" may refer to an element that is configured to be heated to at least 50, 100, 150, 200, 250, or 300 degrees Celsius.

[0131] As used herein, the term "coupled or coupleable" is used to indicate that the cartridge and the device can be coupled to and separated from each other without significant damage to the device or the cartridge.

[0132] 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.

[0133] Example Ex1: An aerosol generating device for coupling to a cartridge, the aerosol generating device comprising:

[0134] a cartridge coupling portion for engaging a cartridge containing an aerosol-forming substrate;

[0135] an air flow passage defined between the air inlet and the air outlet; and

[0136] A heater assembly comprising a fluid permeable heating element configured to heat an aerosol-forming substrate from the cartridge, wherein the heater assembly comprises a first side and a second side, the first side being opposite to the second side, wherein the first side forms at least a portion of a surface of a wall of the airflow passageway, and wherein the second side forms a portion of the cartridge coupling portion and is configured to contact the cartridge to receive the aerosol-forming substrate.

[0137] Example Ex2: An aerosol generating device according to example Ex1, wherein the air inlet is defined in a side wall of the device.

[0138] Example Ex3: An aerosol generating device according to example Ex2, wherein the air outlet is defined in an end wall of the device.

[0139] Example Ex4: An aerosol generating device according to example Ex3, wherein the side walls of the device extend perpendicularly to the end walls of the device.

[0140] Example Ex5: An aerosol generating device according to any one of Examples Ex1 to Ex4, wherein the second side of the heater assembly is located outside the airflow passage.

[0141] Example Ex6: An aerosol generating device according to any one of Examples Ex1 to Ex5, wherein the air outlet is configured to align with an opening in the barrel.

[0142] Example Ex7: An aerosol generating device according to any one of Examples Ex1 to Ex6, wherein the heating component is a planar heater component.

[0143] Example Ex8: An aerosol generating device according to any one of Examples Ex1 to Ex7, wherein the heating element is a planar heating element.

[0144] Example Ex9: An aerosol generating device according to example Ex8, wherein the heating element is perpendicular to the longitudinal axis of the device.

[0145] Example Ex10: An aerosol generating device according to any one of Examples Ex1 to Ex9, wherein the heating element comprises a mesh.

[0146] Example Ex11: An aerosol generating device according to any one of Examples Ex1 to Ex10, wherein the heating element comprises a porous material.

[0147] Example Ex12: An aerosol generating device according to any one of Examples Ex1 to Ex11, wherein the heating element comprises at least one filament.

[0148] Example Ex13: An aerosol generating device according to example Ex12, wherein the at least one filament has a diameter of 0.1 mm to 0.5 mm.

[0149] Example Ex14: An aerosol generating device according to example Ex12, wherein the at least one filament has a diameter of 0.02 mm to 0.2 mm.

[0150] Example Ex15: An aerosol generating device according to any one of Examples Ex1 to EX14, wherein the total resistance of the heating element is 0.1 ohm to 5 ohm, preferably 0.4 ohm to 2 ohm.

[0151] Example Ex16: An aerosol generating device according to any one of Examples Ex1 to Ex15, wherein the heating element comprises stainless steel.

[0152] Example Ex17: An aerosol generating device according to any one of Examples Ex1 to Ex16, wherein the heating element comprises a ferrimagnetic material or a ferromagnetic material.

[0153] Example Ex18: An aerosol generating device according to any one of Examples Ex1 to Ex17, wherein the heating element is coated with a corrosion-resistant material.

[0154] Example Ex19: An aerosol generating device according to any one of Examples Ex1 to Ex18, wherein the heating element is coated with a ceramic material.

[0155] Example Ex20: An aerosol generating device according to any one of Examples Ex1 to Ex19, wherein the heater assembly is configured to contact the wicking portion of the cartridge.

[0156] Example Ex21: An aerosol generating device according to any one of Examples Ex1 to Ex20, wherein the heater assembly comprises a support element, wherein the support element comprises a thermally conductive material in thermal contact with the heating element.

[0157] Example Ex22: An aerosol generating device according to example Ex21, wherein the support element is configured to absorb heat generated by the heating element.

[0158] Example Ex23: An aerosol generating device according to example Ex21 or 22, wherein the support element comprises at least one of aluminum, copper, brass, gold, silver or a thermally conductive ceramic.

[0159] Example Ex24: An aerosol generating device according to any one of Examples Ex21 to Ex23, wherein the thermal conductivity of the support element is at least 10 W / mK.

[0160] Example Ex25: An aerosol generating device according to example Ex24, wherein the thermal conductivity of the support element is at least 50 W / mK.

[0161] Example Ex26: An aerosol generating device according to example Ex25, wherein the thermal conductivity of the support element is at least 200 W / mK.

[0162] Example Ex27: An aerosol generating device according to any one of Examples Ex21 to Ex26, wherein the support element comprises at least one support pin.

[0163] Example Ex28: An aerosol generating device according to example Ex27, wherein the heating element is engaged with the at least one support pin.

[0164] Example Ex29: An aerosol generating device according to example Ex27 or 28, wherein the at least one support pin is cylindrical.

[0165] Example Ex30: An aerosol generating device according to example Ex29, wherein the at least one support pin has a diameter of 0.5 mm to 5 mm, preferably 1 to 2 mm.

[0166] Example Ex31: An aerosol generating device according to any one of Examples Ex1 to Ex30, wherein the heater assembly further comprises a heater holder.

[0167] Example Ex32: An aerosol generating device according to example Ex31, wherein the heater holder comprises an upper plate and a lower plate.

[0168] Example Ex33: An aerosol generating device according to example Ex32, wherein the heating element is located between the upper plate and the lower plate.

[0169] Example Ex34: An aerosol generating device according to any one of Examples Ex31 to Ex33, wherein the heater holder has an aperture defined therethrough.

[0170] Example Ex35: An aerosol generating device according to example Ex34, wherein the orifice is defined through the upper plate and the lower plate.

[0171] Example Ex36: An aerosol generating device according to example Ex34 or Ex35, wherein the heating element spans at least a portion of the orifice.

[0172] Example Ex37: An aerosol generating device according to any one of Examples Ex34 to Ex36, wherein the support element is positioned adjacent to the orifice.

[0173] Example Ex38: The aerosol generating device according to any one of Examples Ex1 to Ex37 further includes a first electrical connector and a second electrical connector, wherein the first electrical connector and the second electrical connector are configured to supply power to the heating element, and the heating element is configured for resistive heating.

[0174] Example Ex39: An aerosol generating device according to example Ex38, wherein the electrical connector is positioned to make electrical contact with the heating element at a distance from the orifice that is greater than the distance from the support element to the orifice.

[0175] Example Ex40: An aerosol generating device according to example Ex38, wherein the first electrical connector and the second electrical connector are positioned adjacent to the orifice.

[0176] Example Ex41: An aerosol generating device according to example Ex40, wherein the support element is in contact with the heating element at a distance from the orifice that is greater than the distances of the first electrical connector and the second electrical connector from the orifice.

[0177] Example Ex42: An aerosol generating device according to any one of Examples Ex34 to Ex41, wherein the cross-sectional area of ​​the orifice is 4 mm 2 Up to 1000 mm 2 .

[0178] Example Ex43: An aerosol generating device according to Example Ex42, wherein the cross-sectional area of ​​the orifice is 9 mm 2 Up to 400 mm 2 .

[0179] Example Ex44: An aerosol generating device according to Example Ex43, wherein the cross-sectional area of ​​the orifice is 16 mm 2 Up to 100 mm 2 .

[0180] Example Ex45: An aerosol generating device according to any one of Examples Ex31 to Ex44, wherein the heater holder is electrically insulating.

[0181] Example Ex46: An aerosol generating device according to example Ex45, wherein the heater holder has a thermal conductivity of 1 W / mK or less.

[0182] Example Ex47: An aerosol generating device according to example Ex45 or Ex46, wherein the heater holder comprises a heat-resistant polymer.

[0183] Example Ex48: An aerosol generating device according to any one of Examples Ex45 to Ex47, wherein the heater holder comprises PEEK.

[0184] Example Ex49: An aerosol generating device according to any one of Examples Ex45 to Ex48, wherein the heater holder comprises LCP.

[0185] Example Ex50: An aerosol generating device according to any one of Examples Ex45 to Ex49, wherein the heater holder comprises ceramic.

[0186] Example Ex51: An aerosol generating device according to example Ex50, wherein the heater holder comprises aluminum oxide.

[0187] Example Ex52: An aerosol generating device according to example Ex50 or 51, wherein the heater holder comprises zirconium oxide.

[0188] Example Ex53: An aerosol generating device according to any one of Examples Ex1 to Ex52, wherein the heater assembly comprises a wicking element.

[0189] Example Ex54: An aerosol generating device according to any one of Examples Ex1 to Ex53, wherein the heating element comprises a susceptor material configured for inductive heating.

[0190] Example Ex55: An aerosol generating device according to any one of Examples Ex1 to Ex54, further comprising a power source.

[0191] Example Ex56: An aerosol generating device according to any one of Examples Ex1 to Ex55, further comprising a control circuit.

[0192] Example Ex57: An aerosol generating device according to any one of Examples Ex1 to Ex56, wherein the aerosol generating device is a handheld aerosol generating device.

[0193] Example Ex58: An aerosol generating device according to any one of Examples Ex1 to Ex57, wherein the heating element is airflow actuated.

[0194] Example Ex59: An aerosol generating device according to any one of Examples Ex1 to Ex58, wherein the heating element is puff-activated.

[0195] Example Ex60: An aerosol-generating device according to any one of Examples Ex1 to Ex59, wherein the heating element is configured to heat a fluid aerosol-forming substrate.

[0196] Example Ex61: An aerosol-generating device according to any one of Examples Ex1 to Ex60, wherein the heating element is configured to heat the liquid aerosol-forming substrate.

[0197] Example Ex62: An aerosol generating device according to any one of Examples Ex1 to Ex61, wherein the heater assembly comprises a compressible element, wherein the compressible element is configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0198] Example Ex63: An aerosol generating device according to example Ex62, wherein the compressible element is a spring.

[0199] Example Ex64: An aerosol generating device according to example Ex62, wherein the compressible element is a compressible wicking element located on the second side of the heater assembly.

[0200] Example Ex65: A heater assembly for an aerosol generating device, the heater assembly comprising:

[0201] a heater holder, the heater holder comprising an aperture;

[0202] a heating element spanning at least a portion of the orifice;

[0203] a first electrical connector and a second electrical connector in electrical contact with the heating element; and

[0204] A support element includes a thermally conductive material in thermal contact with the heating element.

[0205] Example Ex66: A heater assembly according to example Ex65, wherein the heater assembly is a planar heater assembly.

[0206] Example Ex67: A heater assembly according to example Ex65 or 66, wherein the heating element is a planar heating element.

[0207] Example Ex68: A heater assembly according to any one of Examples Ex65 to Ex67, wherein the heating element comprises a mesh.

[0208] Example Ex69: A heater assembly according to any one of Examples Ex65 to Ex68, wherein the heating element comprises a porous material.

[0209] Example Ex70: A heater assembly according to any one of Examples Ex65 to Ex69, wherein the heating element comprises at least one wire.

[0210] Example Ex71: The heater assembly according to any one of Examples Ex65 to Ex70, wherein the at least one wire has a diameter of 0.1 mm to 0.5 mm.

[0211] Example Ex72: The heater assembly according to any one of Examples Ex65 to Ex70, wherein the at least one wire has a diameter of 0.02 mm to 0.2 mm.

[0212] Example Ex73: The heater assembly according to any one of Examples Ex65 to Ex72, wherein the total resistance of the heating element is 0.1 ohm to 5 ohms, preferably 0.4 ohm to 2 ohms.

[0213] Example Ex74: A heater assembly according to any one of Examples Ex65 to Ex73, wherein the heating element comprises stainless steel.

[0214] Example Ex75: A heater assembly according to any one of Examples Ex65 to Ex74, wherein the heating element comprises a ferrimagnetic material or a ferromagnetic material.

[0215] Example Ex76: The heater assembly according to any one of Examples Ex65 to Ex75, wherein the heating element is coated with a corrosion-resistant material.

[0216] Example Ex77: The heater assembly according to any one of Examples Ex65 to Ex76, wherein the heating element is coated with a ceramic material.

[0217] Example Ex78: The heater assembly according to any one of Examples Ex65 to Ex77, wherein the support element is configured to absorb heat generated by the heating element.

[0218] Example Ex79: The heater assembly according to any one of Examples Ex65 to Ex78, wherein the support element comprises at least one of aluminum, copper, brass, gold, silver, or a thermally conductive ceramic.

[0219] Example Ex80: The heater assembly according to any one of Examples Ex65 to Ex79, wherein the thermal conductivity of the support element is at least 10 W / mK.

[0220] Example Ex81: The heater assembly according to any one of Examples Ex65 to Ex80, wherein the thermal conductivity of the support element is at least 50 W / mK.

[0221] Example Ex82: The heater assembly according to any one of Examples Ex65 to Ex81, wherein the thermal conductivity of the support element is at least 200 W / mK.

[0222] Example Ex83: The heater assembly according to any one of Examples Ex65 to Ex82, wherein the support element comprises at least one support pin.

[0223] Example Ex84: A heater assembly according to example Ex83, wherein the heating element is engaged with the at least one support pin.

[0224] Example Ex85: A heater assembly according to example Ex83 or 84, wherein the at least one support pin is cylindrical.

[0225] Example Ex86: A heater assembly according to example Ex85, wherein the at least one support pin has a diameter of 0.5 mm to 5 mm, preferably 1 to 2 mm.

[0226] Example Ex87: A heater assembly according to any one of Examples Ex65 to Ex86, wherein the heater holder comprises an upper plate and a lower plate.

[0227] Example Ex88: The heater assembly according to example Ex87, wherein the heating element is located between the upper plate and the lower plate.

[0228] Example Ex89: A heater assembly according to example Ex87 or Ex88, wherein the aperture is defined through the upper plate and the lower plate.

[0229] Example Ex90: The heater assembly according to any one of Examples Ex65 to Ex89, wherein the first electrical connector and the second electrical connector are configured to supply power to the heating element, and the heating element is configured for resistive heating.

[0230] Example Ex91: The heater assembly according to any one of Examples Ex65 to Ex90, wherein the support element is positioned adjacent to the orifice.

[0231] Example Ex92: The heater assembly according to any one of Examples Ex65 to Ex91, wherein the electrical connector is positioned to be in thermal contact with the heating element at a distance from the aperture that is greater than a distance from the support element to the aperture.

[0232] Example Ex93: The heater assembly according to any one of Examples Ex65 to Ex90, wherein the first electrical connector and the second electrical connector are adjacent to the aperture.

[0233] Example Ex94: The heater assembly according to Example Ex93, wherein the support element contacts the heating element at a distance from the aperture that is farther than the distances of the first electrical connector and the second electrical connector from the aperture.

[0234] Example Ex95: A heater assembly according to any one of Examples Ex65 to Ex94, wherein the cross-sectional area of ​​the orifice is 4 mm 2 Up to 1000 mm 2 .

[0235] Example Ex96: A heater assembly according to Example Ex95, wherein the cross-sectional area of ​​the orifice is 9 mm 2 Up to 400 mm 2 .

[0236] Example Ex97: A heater assembly according to Example Ex96, wherein the cross-sectional area of ​​the orifice is 16 mm 2 Up to 100 mm 2 .

[0237] Example Ex98: A heater assembly according to any one of Examples Ex65 to Ex97, wherein the heater holder is electrically insulating.

[0238] Example Ex99: The heater assembly according to any one of Examples Ex65 to Ex98, wherein the heater holder has a thermal conductivity of 1 W / mK or less.

[0239] Example Ex100: The heater assembly according to any one of Examples Ex65 to Ex99, wherein the heater holder comprises a heat-resistant polymer.

[0240] Example Ex101: A heater assembly according to any one of Examples Ex65 to Ex100, wherein the heater holder comprises PEEK.

[0241] Example Ex102: A heater assembly according to any one of Examples Ex65 to Ex101, wherein the heater holder comprises an LCP.

[0242] Example Ex103: A heater assembly according to any one of Examples Ex65 to Ex102, wherein the heater holder comprises ceramic.

[0243] Example Ex104: The heater assembly according to any one of Examples Ex65 to Ex103, wherein the heater holder comprises aluminum oxide.

[0244] Example Ex105: The heater assembly according to any one of Examples Ex65 to Ex104, wherein the heater holder comprises zirconium oxide.

[0245] Example Ex106: A heater assembly according to any one of Examples Ex65 to Ex105, wherein the heater assembly is configured to heat a fluid aerosol-forming substrate.

[0246] Example Ex107: A heater assembly according to any one of Examples Ex65 to Ex106, wherein the heater assembly is configured to heat a liquid aerosol-forming substrate.

[0247] Example Ex108: The heater assembly according to any one of Examples Ex65 to Ex107, further comprising a compressible element, wherein the compressible element is configured to be compressed when the heater assembly receives a supply of an aerosol-forming substrate.

[0248] Example Ex109: A heater assembly according to example Ex108, wherein the compressible element is a spring.

[0249] Example Ex110: A heater assembly according to example Ex108, wherein the compressible element is a compressible wicking element.

[0250] Example Ex111: A cartridge configured to be coupled to an aerosol generating device as defined in any one of Examples Ex1 to Ex64, the cartridge comprising:

[0251] an aerosol-forming substrate; and a wicking material in fluid communication with the aerosol-forming substrate, wherein the wicking material forms part of the outer surface of the barrel and is configured to contact the aerosol generating device.

[0252] Example Ex112: A cartridge according to Example Ex111, comprising a cartridge air flow passage defined between a cartridge air inlet and a cartridge air outlet.

[0253] Example Ex113: The cartridge according to example Ex112, comprising a mouthpiece, wherein the mouthpiece comprises the cartridge air outlet.

[0254] Example Ex114: The cartridge according to any one of Examples Ex111 to Ex113, further comprising a removable seal covering the wicking material, wherein the removable seal is configured to be removed by a user.

[0255] Example Ex114a: An aerosol generating system comprising:

[0256] An aerosol generating device according to any one of Examples Ex1 to Ex64; and

[0257] A cartridge, comprising:

[0258] An aerosol-forming substrate is in fluid communication with a wicking material, wherein the wicking material forms a portion of the outer surface of the barrel.

[0259] Example Ex115: An aerosol generating system, comprising:

[0260] A cartridge, comprising:

[0261] an aerosol-forming substrate in fluid communication with a wicking material, wherein the wicking material forms a portion of the outer surface of the barrel; and

[0262] An aerosol generating device, the aerosol generating device comprising:

[0263] a cartridge coupling portion for engaging the cartridge comprising an aerosol-forming substrate;

[0264] an air flow passage defined between a device air inlet and a device air outlet; and

[0265] A heater assembly comprising a fluid permeable heating element configured to heat an aerosol-forming substrate from the cartridge, wherein the heater assembly comprises a first side and a second side, the first side being opposite to the second side, wherein the first side forms at least a portion of a surface of a wall of the airflow passageway, and wherein the second side forms a portion of a coupling portion of the cartridge and is configured to contact a wicking material of the cartridge to receive the aerosol-forming substrate.

[0266] Example Ex116: An aerosol generating system according to example Ex115, wherein the cartridge comprises a cartridge air inlet and a cartridge air outlet, wherein the cartridge air inlet is aligned with the device air outlet.

[0267] Example Ex117: An aerosol generating system according to example Ex116, further comprising a mouthpiece, wherein the mouthpiece comprises the cartridge air outlet.

[0268] Example Ex118: An aerosol generating system according to example Ex117, wherein the system is suction actuated.

[0269] Example Ex119: An aerosol generating system according to example Ex118, wherein the aerosol-forming substrate is a fluid.

[0270] Example Ex120: An aerosol generating system according to any one of Examples Ex115 to Ex119, wherein the device air inlet is defined in a side wall of the aerosol generating device.

[0271] Example Ex121: An aerosol generating system according to example Ex120, wherein the device air outlet is defined in an end wall of the aerosol generating device.

[0272] Example Ex122: An aerosol generating system according to example Ex121, wherein the side walls of the aerosol generating device extend perpendicularly to the end walls of the aerosol generating device.

[0273] Example Ex123: An aerosol generating system according to any one of Examples Ex115 to Ex122, wherein the second side of the heater assembly is located outside the airflow pathway.

[0274] Example Ex124: An aerosol generating system according to any one of Examples Ex115 to Ex123, wherein the device air outlet is configured to align with the opening in the barrel.

[0275] Example Ex125: An aerosol generating system according to any one of Examples Ex115 to Ex124, wherein the heating component is a planar heater component.

[0276] Example Ex126: An aerosol generating system according to any one of Examples Ex115 to Ex125, wherein the heating element is a planar heating element.

[0277] Example Ex127: An aerosol generating system according to example Ex126, wherein the heating element is perpendicular to the longitudinal axis of the aerosol generating device.

[0278] Example Ex128: An aerosol generating system according to any one of Examples Ex115 to Ex127, wherein the heating element comprises a mesh.

[0279] Example Ex129: An aerosol generating system according to any one of Examples Ex115 to Ex128, wherein the heating element comprises a porous material.

[0280] Example Ex130: An aerosol generating system according to any one of Examples Ex115 to Ex129, wherein the heating element comprises at least one filament.

[0281] Example Ex131: An aerosol generating system according to example Ex130, wherein the at least one filament has a diameter of 0.1 mm to 0.5 mm.

[0282] Example Ex132: An aerosol generating system according to example Ex130, wherein the at least one filament has a diameter of 0.02 mm to 0.2 mm.

[0283] Example Ex133: An aerosol generating system according to any one of Examples Ex115 to Ex132, wherein the total resistance of the heating element is 0.1 ohm to 5 ohm, preferably 0.4 ohm to 2 ohm.

[0284] Example Ex134: An aerosol generating system according to any one of Examples Ex115 to Ex133, wherein the heating element comprises stainless steel.

[0285] Example Ex135: An aerosol generating system according to any one of Examples Ex115 to Ex134, wherein the heating element comprises a ferrimagnetic material or a ferromagnetic material.

[0286] Example Ex136: An aerosol generating system according to any one of Examples Ex115 to Ex135, wherein the heating element is coated with a corrosion-resistant material.

[0287] Example Ex137: An aerosol generating system according to any one of Examples Ex115 to Ex136, wherein the heating element is coated with a ceramic material.

[0288] Example Ex138: An aerosol generating system according to any one of Examples Ex115 to Ex137, wherein the heater assembly is configured to contact the wicking portion of the cartridge.

[0289] Example Ex139: An aerosol generating system according to any one of Examples Ex115 to Ex138, wherein the heater assembly comprises a support element, wherein the support element comprises a heat conductive material in thermal contact with the heating element.

[0290] Example Ex140: An aerosol generating system according to example Ex139, wherein the support element is configured to absorb heat generated by the heating element.

[0291] Example Ex141: An aerosol generating system according to example Ex139 or Ex140, wherein the support element comprises at least one of aluminum, copper, brass, gold, silver, or a thermally conductive ceramic.

[0292] Example Ex142: An aerosol generating system according to any one of Examples Ex139 to Ex141, wherein the thermal conductivity of the support element is at least 10 W / mK.

[0293] Example Ex143: An aerosol generating system according to example Ex142, wherein the thermal conductivity of the support element is at least 50 W / mK.

[0294] Example Ex144: An aerosol generating system according to example Ex143, wherein the thermal conductivity of the support element is at least 200 W / mK.

[0295] Example Ex145: An aerosol generating system according to any one of Examples Ex139 to Ex144, wherein the support element comprises at least one support pin.

[0296] Example Ex146: An aerosol generating system according to example Ex145, wherein the heating element is engaged with the at least one support pin.

[0297] Example Ex147: An aerosol generating system according to example Ex139 or Ex146, wherein the at least one support pin is cylindrical.

[0298] Example Ex148: An aerosol generating system according to example Ex147, wherein the at least one support pin has a diameter of 0.5 mm to 5 mm, preferably 1 to 2 mm.

[0299] Example Ex149: An aerosol generating system according to any one of Examples Ex115 to Ex148, wherein the heater assembly further comprises a heater holder.

[0300] Example Ex150: An aerosol generating system according to example Ex149, wherein the heater holder comprises an upper plate and a lower plate.

[0301] Example Ex151: An aerosol generating system according to example Ex150, wherein the heating element is located between the upper plate and the lower plate.

[0302] Example Ex152: An aerosol generating system according to any one of Examples Ex149 to Ex151, wherein the heater holder has an aperture defined therethrough.

[0303] Example Ex153: An aerosol generating system according to example Ex152, wherein the orifice is defined through the upper plate and the lower plate.

[0304] Example Ex154: An aerosol generating system according to example Ex152 or Ex153, wherein the heating element spans at least a portion of the orifice.

[0305] Example Ex155: An aerosol generating system according to any one of Examples Ex152 to Ex154, wherein the support element is positioned adjacent to the orifice.

[0306] Example Ex156: An aerosol generating system according to any one of Examples Ex115 to Ex155, comprising a first electrical connector and a second electrical connector, wherein the first electrical connector and the second electrical connector are configured to supply power to the heating element, and the heating element is configured for resistive heating.

[0307] Example Ex157: An aerosol generating system according to example Ex156, wherein the electrical connector is positioned to be in thermal contact with the heating element at a distance from the orifice that is greater than the distance of the support element from the orifice.

[0308] Example Ex158: An aerosol generating system according to examples Ex156 to Ex157, wherein the first electrical connector and the second electrical connector are positioned adjacent to the orifice.

[0309] Example Ex159: An aerosol generating system according to example Ex158, wherein the support element is in contact with the heating element at a distance from the orifice that is greater than the distances of the first electrical connector and the second electrical connector from the orifice.

[0310] Example Ex160: An aerosol generating system according to any one of Examples Ex152 to Ex159, wherein the cross-sectional area of ​​the orifice is 4 mm 2 Up to 1000 mm 2 .

[0311] Example Ex161: An aerosol generating system according to Example Ex160, wherein the cross-sectional area of ​​the orifice is 9 mm 2 Up to 400 mm 2 .

[0312] Example Ex162: An aerosol generating system according to Example Ex161, wherein the cross-sectional area of ​​the orifice is 16 mm 2 Up to 100 mm 2 .

[0313] Example Ex163: An aerosol generating system according to any one of Examples Ex149 to Ex162, wherein the heater holder is electrically insulating.

[0314] Example Ex164: An aerosol generating system according to example Ex163, wherein the heater holder has a thermal conductivity of 1 W / mK or less.

[0315] Example Ex165: An aerosol generating system according to example Ex163 or Ex164, wherein the heater holder comprises a heat-resistant polymer.

[0316] Example Ex166: An aerosol generating system according to any one of Examples Ex163 to Ex165, wherein the heater holder comprises PEEK.

[0317] Example Ex167: An aerosol generating system according to any one of Examples Ex163 to Ex166, wherein the heater holder comprises LCP.

[0318] Example Ex168: An aerosol generating system according to any one of Examples Ex163 to Ex167, wherein the heater holder comprises ceramic.

[0319] Example Ex169: An aerosol generating system according to example Ex168, wherein the heater holder comprises aluminum oxide.

[0320] Example Ex170: An aerosol generating system according to example Ex168 or Ex169, wherein the heater holder comprises zirconium oxide.

[0321] Example Ex171: An aerosol generating system according to any one of Examples Ex115 to Ex170, wherein the heater assembly comprises a wicking material.

[0322] Example Ex172: An aerosol generating system according to any one of Examples Ex115 to Ex171, wherein the heating element comprises a susceptor material configured for inductive heating.

[0323] Example Ex173: An aerosol generating system according to any one of Examples Ex115 to Ex172, further comprising a power source.

[0324] Example Ex174: An aerosol generating system according to any one of Examples Ex115 to Ex173, further comprising a control circuit.

[0325] Example Ex175: An aerosol generating system according to any one of Examples Ex115 to Ex175, wherein the aerosol generating system is a handheld aerosol generating system.

[0326] Example Ex176: An aerosol generating system according to any one of Examples Ex115 to Ex175, wherein the heating element is airflow actuated.

[0327] Example Ex177: An aerosol generating system according to any one of Examples Ex115 to Ex176, wherein the heating element is puff-actuated.

[0328] Example Ex178: An aerosol generating system according to any one of Examples Ex115 to Ex177, wherein the heating element is configured to heat the liquid aerosol-forming substrate.

[0329] Example Ex179: An aerosol generating system according to any one of Examples Ex115 to Ex178, wherein the heater assembly comprises a compressible element, wherein the compressible element is configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0330] Example Ex180: An aerosol generating system according to example Ex179, wherein the compressible element is a spring.

[0331] Example Ex181: An aerosol generating system according to example Ex179, wherein the compressible element is a compressible wicking element located on the second side of the heater assembly.

[0332] Features of one aspect of the invention may be applied to other aspects of the invention.

[0333] Several examples will now be further described with reference to the accompanying drawings, in which:

[0334] Figure 1 A simplified cross section of an aerosol generating system is shown;

[0335] Figure 2A shows an exploded perspective view of a portion of an aerosol generating system;

[0336] Figure 2B shows a cross-sectional perspective view of a portion of an aerosol generating system;

[0337] Figure 3A shows an exploded perspective view of a heater assembly according to a first embodiment;

[0338] Figure 3B Shows Figure 3A A perspective view of a heater assembly;

[0339] Figure 4A shows an exploded perspective view of a heater assembly according to a second embodiment;

[0340] Figure 4B Shows Figure 4A A perspective view of a heater assembly;

[0341] Figure 5 shows a cross-sectional perspective view of a cartridge according to a first embodiment;

[0342] Fig. 6A shows a cross-sectional perspective view of a cartridge according to a second embodiment; and

[0343] Figure 6B Shows Fig. 6A Perspective view of the barrel.

[0344] Figure 1 A cross-sectional view of an aerosol generating system 700 is shown comprising an aerosol generating device 500 and a cartridge 600. In this example, the aerosol generating system 700 is an electrically operated smoking system, commonly referred to as an electronic cigarette system. The aerosol generating system 700 is a handheld portable system and is of a size comparable to a conventional cigar or cigarette.

[0345] The device 500 includes a battery 560 , such as a lithium iron phosphate battery, and a controller 570 electrically connected to the battery 560 .

[0346] The device 500 includes an air inlet 510, an air outlet 520, and a heater assembly 530. An air flow path is defined between the air inlet 510 and the air outlet 520. The heater assembly 530 is positioned downstream of the air inlet 510 and upstream of the air outlet 520. The heater assembly 530 includes a fluid permeable heating element 540, a first electrical connector and a second electrical connector ( Figure 1 ), the heater holder 550 and the support element ( Figure 1 5). The heating element 540 is a heating wire that spans an aperture in the heater holder 550. The first electrical connector and the second electrical connector are electrically connected to the heating element 540, the battery 560, and the controller 570. The device 500 also includes a compressible element 580, such as a spring.

[0347] The device 500 includes a cartridge coupling portion 502 for engaging a cartridge 600 .

[0348] The cartridge 600 comprises a liquid aerosol-forming substrate in a reservoir 610. In this system, the reservoir 610 is in fluid communication with a ceramic wicking material 620 such that the liquid aerosol-forming substrate can flow from the reservoir 610 to the wicking material 620.

[0349] The cartridge 600 is coupled to the device 500 via a cartridge coupling portion.

[0350] The device air outlet 520 is configured to align with the cartridge air inlet 630. When the device 500 is coupled to the cartridge 600, the device airflow passage connects to the cartridge airflow passage, thereby defining an airflow passage from the device air inlet 510 to the cartridge air outlet 640. The cartridge includes a mouthpiece in which the cartridge air outlet 640 is defined.

[0351] The wicking material 620 is configured to align with the orifice of the heater holder 550. The orifice is circular with a cross-sectional area of ​​4 mm 2 Up to 1000 mm 2 The wicking material 620 also has a circular cross-section so that the wicking material 620 can be easily received by the aperture of the heater holder 550 .

[0352] In use, the user draws on the mouthpiece of the cartridge 600, thereby drawing air into the device air inlet 510. The system is puff-activated, meaning that a puff sensor (not shown), which may be a pressure sensor or an airflow sensor, is located in the system 700. The puff sensor will detect the user's puff and send a signal to the controller 570, which causes power to be supplied from the battery 560 to the heating element 540 via the first and second electrical connectors. This causes current to flow through the heating element 540, thereby resistively heating the heating element 540. In other examples, the aerosol generating system may include a button that the user presses to send a signal to the controller to supply power from the battery to the heating element 540.

[0353] When the heating element 540 resistively heats, the support element conducts the heat away from the heating element 540, where the heating element 540 is in contact with the support element. This will minimize the number of hot spots that occur on the heating element 540, resulting in a relatively uniform temperature across the heating element. When the heating element 540 is heated, it heats the wicking material 620, and thus heats any aerosol-forming substrate contained in the wicking material 620. The heating of the wicking material 620 causes the aerosol-forming substrate to evaporate.

[0354] When the user draws on the tube air outlet 640, air is sucked into the device air inlet 510. When air is drawn through the air passage, air will pass through the heater assembly 530. Air will flow through the first side of the heating element 540, flow through the surface of the wicking material and flow towards the tube air outlet. The evaporated aerosol forms a substrate entrained in the flowing air. Then, the entrained steam cools and condenses to form an aerosol. The aerosol leaves the device airflow passage through the air outlet 520. Then, the aerosol enters the tube 600 through the tube air inlet 630, leaves the tube through the tube air outlet 640, and is delivered to the user's mouth.

[0355] When the liquid aerosol-forming substrate in the wicking material 620 is heated, evaporated and entrained in the airflow, the liquid aerosol-forming substrate from the reservoir 610 enters the wicking material 620. The aerosol-forming substrate from the reservoir 610 effectively replaces the evaporated aerosol-forming substrate. The liquid aerosol-forming substrate from the reservoir 610 may be drawn into the wicking material 620 at least in part by capillary action. This is because the wicking material 620 is a capillary material having a fiber or sponge structure.

[0356] After multiple uses of the aerosol generating system 700, the wicking material may begin to degrade. The user may then separate the cartridge 600 from the device 500. The cartridge 500 may be removed and disposed of. The aerosol generating device 500 may then be reused with a new cartridge.

[0357] Figure 2A A perspective view of a portion of an aerosol generating system 800 is shown. The system 800 includes a cartridge 1000 and an aerosol generating device 900. The aerosol generating device 900 includes a heater assembly. The heater assembly includes: a heater holder including an upper plate 952 and a lower plate 954, a heating element 940, and a support pin 962. A device air inlet 910 is defined in a side wall of the aerosol generating device. A device air outlet 920 is formed in the cartridge coupling portion of the device.

[0358] Figure 2B When the aerosol generating device 900 is coupled to the cartridge 1000, Figure 2A A cross-sectional view of an aerosol generating system 800 is shown. The cartridge 1000 is received by a cartridge coupling portion of the device 900.

[0359] Figure 3A An exploded view of a heater assembly 130 according to a first embodiment is shown. The heater assembly 130 includes a fluid permeable heating element 140, a heater holder 150, and a support element 160. The heater assembly 130 includes a first side 132 and a second side 134, the first side 132 being opposite the second side 134.

[0360] The heater holder 150 includes an upper plate 152 and a lower plate 154, wherein the heating element 140 is located between the upper plate and the lower plate. Both the upper plate 152 and the lower plate 154 include an aperture. When assembled, the aperture of the upper plate 152 and the aperture of the lower plate 154 are aligned, thereby forming an aperture through the heater assembly 130. The cross-sectional area of ​​the aperture is 9 mm 2 Up to 400 mm 2 , preferably 16 mm 2 Up to 100 mm 2 The heater holder 150 comprises a heat resistant polymer, in particular PEEK or LCP. In other examples, the heater holder may comprise a ceramic, such as alumina or zirconia.

[0361] The heating element 140 spans at least a portion of the orifice. The heating element is a stainless steel wire (heating wire) configured for resistive heating. In other examples, the heating element may include a mesh. The mesh may include multiple wires. The heating element may be coated with a corrosion resistant material, such as a ceramic material. Figure 3A In the example shown in FIG. 1 , the heating wire 140 has a diameter of 0.1 mm to 0.5 mm. The heating element has a total resistance of 0.1 to 5 ohms, preferably 0.4 to 2 ohms.

[0362] The support element 160 includes six support pins 162. The support pins include a thermally conductive material, such as aluminum, copper, brass, gold-coated metal, silver-coated metal, or a thermally conductive ceramic. The thermal conductivity of the support pins is at least 10 W / mK, preferably at least 50 W / mK, and more preferably at least 200 W / mK. The support pins 162 provide mechanical support to the heating element 140. The support pins 162 also act as thermal conductors to conduct heat away from the heating element 140, particularly away from hot spots in the heating element 140. The support pins 162 are positioned adjacent to the apertures in the upper plate 152 and the lower plate 154.

[0363] The heating assembly further comprises a first electrical connector 170 and a second electrical connector 180. The first electrical connector is in electrical contact with a first end of the heating element. The second electrical connector is in electrical contact with a second end of the heating element. The first electrical connector and the second electrical connector are configured to supply power to the heating element 140.

[0364] Figure 3B Shows the assembly Figure 3A The heater assembly. Figure 3B As shown in , an upper plate 152 and a lower plate 154 are attached to form a planar heating assembly.

[0365] The heater assembly 130 is configured such that in use, power is supplied to the heating element 140 via the first electrical connector 170 and the second electrical connector 180. The power resistively heats the heating element 140. With the heating element 140 in physical contact with the support pin 162, the support pin 162 conducts heat away from the heating element. Thus, temperature peaks or hot spots in the heating element are reduced. A substantially uniform temperature is achieved across the heating element.

[0366] The heater assembly 130 is manufactured by pressing or gluing the support pin 162 onto the lower plate 154. The heating element (wire) 140 is wound around the support pin 162 and held under tension, thereby forming Figure 1 A and 1B. A first electrical connector 170 is applied to a first end of the heating element 140, and a second electrical connector 180 is applied to a second end of the heating element 140. An upper plate 152 is then applied on top of the other elements. The upper plate 152 and the lower plate 154 can be attached by plastic welding the upper plate 152 and the lower plate 154. Alternatively, they can be joined by applying an adhesive between the upper plate 152 and the lower plate 154. Alternatively or in addition, by adding fasteners, such as screws or rivets, between the upper plate 152 and the lower plate 154.

[0367] Figure 4A and Figure 4BA heater assembly 230 is shown according to a second embodiment of the present disclosure. The heater assembly 230 includes a fluid permeable heating element 240, a heater holder 250, and a support element 260. The heater assembly 230 includes a first side 232 and a second side 234, the first side 232 being opposite to the second side 234.

[0368] Figure 4A The embodiment shown in shows a first electrical connector 270 and a second electrical connector 280 adjacent to an orifice in an upper plate and an orifice in a lower plate. The support element 260 includes a support pin 262. In this embodiment, the support pin 262 is positioned at a distance from the orifice greater than the distance of the electrical connector from the orifice. The first electrical connector 270 and the second electrical connector 280 are positioned adjacent to the orifice, and the heating element 240 spans the orifice. The heating element is a heating wire having a diameter of 0.02 mm to 0.2 mm and is wound around the support pin 262. The first electrical connector 270 and the second electrical connector 280 are applied to the heating wire and are connected in parallel.

[0369] Figure 4B Shown when assembled Figure 4A The heater assembly of the present invention. When the heater assembly 230 is used, power is supplied to the heating element 240 via the first electrical connector 270 and the second electrical connector 280. The power delivers current to the heating element 240, which is configured to resistively heat. In the case where the heating element 240 is in physical contact with the support pin 262, the support pin 262 conducts heat away from the heating element. Therefore, the temperature peak or hot spot in the heating element is reduced. In this configuration, the current flows along the portion of the heating wire between the first electrical connector 270 and the second electrical connector 280. Due to the position of the first electrical connector 270 and the second electrical connector 280, the current does not flow in the portion of the heating element in contact with the support pin 262. In this embodiment, the first electrical connector 270 and the second electrical connector 280 conduct heat away from the heating element 240 and are used to reduce the hot spots in the heating element 240. In particular, they conduct heat away from the portion of the heating element 230 with which they are in physical contact, which in this case is also the portion in contact with the heater holder 250, and is therefore an area where hot spots may occur.

[0370] Figure 5Shown is a cartridge 300. The cartridge 300 includes an aerosol-forming substrate stored in a reservoir 310 and a wicking material 320 that is in fluid communication with the aerosol-forming substrate. The reservoir 310 can be any size or shape suitable for accommodating an aerosol-forming substrate in the cartridge 300. In this example, the aerosol-forming substrate is a liquid. A portion of the reservoir 310 is in contact with the wicking material 320. This portion is configured to allow fluid to pass between the reservoir 310 and the wicking material 320. This portion of the reservoir 310 has an opening 350 defined therethrough to allow fluid to pass through. During use of the system, the fluid aerosol-forming substrate can flow from the reservoir to the wicking material, and a gas such as air can flow to the reservoir through the wicking material to allow pressure to balance within the system.

[0371] The wicking material 320 is a porous ceramic and forms part of the outer surface of the cartridge 300 and is configured to contact the aerosol generating device. The wicking material is configured to absorb a fluid aerosol-forming substrate and transport the fluid aerosol-forming substrate through the wicking material.

[0372] The cartridge 300 also includes a cartridge air inlet 330 and a cartridge air outlet 340. The cartridge air flow path is defined between the cartridge air inlet 330 and the cartridge air outlet 340. The cartridge also includes a mouthpiece 360. The mouthpiece includes the cartridge air outlet. In use, when the cartridge is engaged with the aerosol generating device, a user can draw on the mouthpiece of the cartridge to draw air through the system and out of the air outlet of the cartridge.

[0373] Fig. 6A and Figure 6B A second embodiment of a cartridge 400 comprising a removable seal is shown. The wicking material 420 forms part of the outer surface of the cartridge 400 and is configured to contact the aerosol generating device. The cartridge 400 comprises a protruding wall 470 around the periphery of the device coupling portion of the cartridge 400. The protruding wall 470 protrudes further from the cartridge than the wicking material 420. The cartridge air inlet 430 comprises a partition wall 480 protruding from the surface of the device coupling portion.

[0374] The cartridge 400 includes a removable seal 460 attached to a dividing wall 480 and a protruding wall 470 of the cartridge.

[0375] The removable seal is configured to be removed by a user before cartridge 400 is coupled to a device.

[0376] Figure 6B Shows Fig. 6A A cartridge in which the removable seal 460 is peeled away from the cartridge 400 . Figure 6B The removable seal 460 is shown partially removed from the cartridge.

[0377] For the purpose of this specification and the appended claims, unless otherwise indicated, all numbers representing amount, quantity, percentage, etc. should be understood to be modified by the term "about" in all cases. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may be specifically listed or may not be listed in this article. Therefore, in this article, the number A is understood to be ± 10% of A. In this article, the number A may be considered to be included in the numerical value within the general standard error of the measurement of the property modified by the number A. In some cases used in the appended claims, the number A may deviate from the percentage listed above, provided that the amount of A deviation will not substantially affect the basic characteristics and novel features of the invention claimed for protection. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may be specifically listed or may not be listed in this article.

Claims

1. An aerosol generating device for coupling to a cartridge, the aerosol generating device comprising: a cartridge coupling portion for engaging a cartridge containing an aerosol-forming substrate; an air flow passage defined between an air inlet and an air outlet; as well as a heater assembly comprising a fluid permeable heating element configured to heat an aerosol-forming substrate from the cartridge, wherein the heater assembly comprises a first side and a second side, the first side being opposite the second side, wherein the first side forms at least a portion of a surface of a wall of the airflow passageway, and wherein the second side forms a portion of the cartridge coupling portion and is configured to contact the cartridge to receive the aerosol-forming substrate, Wherein the heater assembly comprises a support element, wherein the support element comprises a thermally conductive material in thermal contact with the heating element.

2. An aerosol generating device according to claim 1, wherein the support element comprises at least one of aluminium, copper, brass, gold, silver or a thermally conductive ceramic.

3. An aerosol generating device according to any preceding claim, wherein the heater assembly further comprises a heater holder comprising a heat resistant polymer.

4. An aerosol generating device according to claim 3, wherein the heater holder has an aperture defined therethrough.

5. An aerosol generating device according to claim 4, wherein the heater holder comprises an upper plate and a lower plate, and the aperture is defined through the upper plate and the lower plate.

6. An aerosol generating device according to claim 4 or 5, wherein the heating element spans at least a portion of the orifice.

7. An aerosol generating device according to any preceding claim, wherein the heating element is a heating wire having a diameter of 0.1 mm to 0.5 mm or a diameter of 0.02 mm to 0.2 mm.

8. An aerosol generating device according to any preceding claim, further comprising a first electrical connector and a second electrical connector, wherein the first electrical connector and the second electrical connector are configured to supply power to the heating element, and the heating element is configured for resistive heating.

9. An aerosol generating device according to claim 8, wherein the first electrical connector and the second electrical connector are located adjacent to the orifice.

10. An aerosol generating device according to any one of claims 1 to 8, wherein the support element is located adjacent to the orifice.

11. A heater assembly for an aerosol generating device, the heater assembly comprising: a heater holder, the heater holder comprising an aperture; a heating element spanning at least a portion of the orifice; a first electrical connector and a second electrical connector in electrical contact with the heating element; as well as A support element includes a thermally conductive material in thermal contact with the heating element.

12. An aerosol generating system comprising: An aerosol generating device according to any one of claims 1 to 10; as well as A cartridge, comprising: An aerosol-forming substrate is in fluid communication with a wicking material, wherein the wicking material forms a portion of the outer surface of the barrel.

13. An aerosol generating system according to claim 12, further comprising a compressible element, wherein the compressible element is configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

14. An aerosol generating system according to claim 12 or 13, further comprising a mouthpiece and a cartridge air flow passage defined between a cartridge air inlet and a cartridge air outlet, wherein the cartridge air inlet is aligned with the device air outlet and the mouthpiece includes the cartridge air outlet.

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