Cartridge with liquid meniscus-forming element for aerosol-generating system

Abstract

A cartridge (10) for an aerosol-generating system, the cartridge (10) comprising an air inlet (32) and an air outlet (38), an airflow passage (26, 48) extending between the air inlet (32) and the air outlet (38), a liquid reservoir (44) comprising a liquid aerosol-forming substrate (42), a heater assembly (12) comprising at least one heating element (16, 18) in fluid communication with the airflow passage (26, 48), the heater assembly (12) is configured to heat a liquid aerosol-forming substrate (42) supplied from a liquid reservoir (44) to a surface of the heater assembly (12) to generate an aerosol. The cartridge further comprises at least one meniscus forming element (101, 102), the at least one meniscus forming element (101, 102) being proximate to the heater assembly (12). Each meniscus-forming element (101, 102) is positioned within the airflow passage (26, 48) and contacts or is spaced apart from a surface of the heater assembly (12) such that, during use, a meniscus of the liquid aerosol-forming substrate (42) is formed between the surface of the heater assembly (12) and the at least one meniscus-forming element (101, 102).

Description

[0001] The present invention relates to a cartridge for an aerosol generating system, an aerosol generating system and an aerosol generating device.

[0002] Aerosol generating systems and devices configured to generate an inhalable aerosol from an aerosol-forming substrate are known in the art. Some previous aerosol generating systems include an aerosol generating device that can be coupled to a cartridge. A typical cartridge used with an aerosol generating device includes an aerosol-forming substrate and a heater assembly, wherein the heater assembly includes a heating element.

[0003] The aerosol-forming substrate can be a liquid. In this case, the tube or device may also include a wicking material that is in fluid communication with the aerosol-forming substrate and in contact with the heating element. The wicking material is configured to transport the liquid aerosol-forming substrate to the heating element. In use, the heating element is configured to evaporate the liquid aerosol-forming substrate. For example, the heating element can be inductively heated. The 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 aerosol generating device generally includes a power supply configured to supply electricity to the heating element. In an aerosol generating system including a device and a tube, the power supply will generally be configured to supply electricity to the heating element via an electrical connector when the device and the tube are connected together.

[0004] In aerosol generating systems of this type, the system is typically configured so that the heating element is only activated when a user draws on the system.

[0005] Near the end of the user's puff, the liquid aerosol-forming substrate present at the heating element may be completely evaporated, and the delivery of the liquid aerosol-forming substrate to the heating element through the wicking material is usually limited by the diffusion rate of the liquid aerosol-forming substrate to the heating element through the wicking element. This diffusion rate of the liquid aerosol-forming substrate to the heating element through the wicking element is usually not fast enough to keep up with the aerosol generation desired by the user. Therefore, when the user takes a long or strong puff on the aerosol generating system or device, the aerosol generation may be reduced near the end of the puff. Reduced aerosol generation and delivery may be detrimental to the overall experience of the user.

[0006] It would therefore be desirable to provide a cartridge for an aerosol generating system, an aerosol generating system and an aerosol generating device which increase the amount of liquid aerosol-forming substrate available for vaporization by a heating element.

[0007] According to a first embodiment of the present disclosure, a cartridge for an aerosol generating system is provided. The cartridge may include an air inlet and an air outlet. The cartridge may include an air flow path extending between the air inlet and the air outlet. The cartridge may include a liquid reservoir, the liquid reservoir including a liquid aerosol-forming substrate. The cartridge may include a heater assembly, the heater assembly including at least one heating element in fluid communication with the air flow path. The heater assembly may be configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to the surface of the heater assembly to generate an aerosol. The cartridge may include at least one meniscus-forming element, at least one meniscus-forming element being close to the heater assembly. Each meniscus-forming element may be positioned in the air flow path. Each meniscus-forming element may contact the surface of the heater assembly or may be spaced apart from the surface of the heater assembly so that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and at least one meniscus-forming element. Advantageously, each meniscus-forming element provides an additional volume of liquid aerosol-forming substrate than that already present in the heater assembly, thereby providing more liquid aerosol-forming substrate available at the heater assembly for vaporization during puffing.

[0008] In addition, each meniscus forming element may provide mechanical support to the heater assembly. This is particularly advantageous if each meniscus forming element contacts the heater assembly. For example, each meniscus forming element may limit deformation of the heater assembly.

[0009] Each meniscus-forming element may contact the surface of the heater assembly, or may be spaced between 0 mm and 3 mm from the surface of the heater assembly. Preferably, each meniscus-forming element contacts the surface of the heater assembly, or is spaced between 0 mm and 1 mm from the surface of the heater assembly. Advantageously, such a distance from the surface of the heater assembly ensures that a meniscus can be reliably formed from the liquid aerosol-forming substrate at room temperature.

[0010] Preferably, each meniscus forming element does not contact the surface of the heater assembly. Preferably, each meniscus forming element is spaced between 0 mm and 3 mm from the surface of the heater assembly and does not contact the surface of the heater assembly. More preferably, each meniscus forming element is spaced between 0 mm and 1 mm from the surface of the heater assembly and does not contact the surface of the heater assembly. Advantageously, each meniscus forming element spaced from the surface of the heater assembly avoids direct contact between the heater assembly and each meniscus forming element, because if the two are in contact, the heat from the heater assembly may damage the meniscus forming element. In addition, this reduces the heat loss that may originally occur from the heater assembly to the meniscus forming element if the two are in contact.

[0011] At least one heating element may form at least a portion of a surface of the heater assembly. Preferably, at least one heating element forms a majority of the surface of the heater assembly. At least one heating element may form the entire surface of the heater assembly. At least one heating element may form the entire surface of the heater assembly located within the airflow path. Each meniscus forming element may contact the surface of at least one heating element, or may be spaced apart from the surface of at least one heating element, such that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the at least one heating element and the at least one meniscus forming element.

[0012] Each meniscus forming element may be an elongated element. Each meniscus forming element may include a tip close to the heater assembly such that each tip contacts or is spaced apart from a surface of the heater assembly and such that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus forming element. Advantageously, having the tip of each meniscus forming element close to the heater assembly ensures that sufficient surface of the heater assembly is exposed to the airflow path so that vapour can be drawn away from the heater assembly and aerosolised in the airflow path.

[0013] The tip may be defined as a sharp end or a rounded end of the meniscus forming element.The tip may additionally or alternatively be defined as the end of an elongated or tapered region of the meniscus forming element.

[0014] The airflow passage may be defined by an airflow passage wall. The airflow passage wall may include an inner surface, and at least one meniscus forming element may extend from the inner surface. Advantageously, this feature may increase the robustness of the cartridge and simplify the manufacture of the cartridge.

[0015] The at least one heating element may comprise a susceptor element configured to be inductively heated. Advantageously, the inductive heating allows a wireless connection between the susceptor element arranged within the cartridge and an aerosol generating device configured to receive the cartridge. In this way, the liquid aerosol-forming substrate contained in the reservoir in the cartridge may be kept completely sealed from any electrical connection during the shelf life and also in operation when coupled to the aerosol generating device.

[0016] At least one heating element may be configured to be resistively heated.

[0017] At least one heating element may comprise at least one fluid permeable heating element. For example, at least one heating element may comprise any one or combination of a perforated plate, a grid, a plurality of filaments or a monofilament with gaps disposed between each filament. The monofilament may, for example, be serpentine shaped. Preferably, at least one heating element comprises at least one mesh heating element. At least one heating element may comprise at least one planar heating element. A planar element may be defined as an element having a significantly greater extension in two orthogonal directions than in a third direction orthogonal to the first two directions.

[0018] Each of the at least one heating element may include a high temperature zone that reaches a maximum temperature during use, and the at least one meniscus forming element may be close to the high temperature zone. Advantageously, due to the increase in the volume of liquid present for aerosolization, the meniscus formed by each of the meniscus forming elements at the high temperature zone may locally reduce the temperature at the high temperature zone. This may ensure that the heating element does not overheat or dry out at the high temperature zone, which may lead to the production of undesirable compounds due to overheating.

[0019] The airflow path may extend in a longitudinal direction so that the direction of the airflow through the airflow path through the heater assembly is in the longitudinal direction. The heater assembly may extend across the airflow path. Advantageously, this may provide a large surface area for heating and evaporating the liquid aerosol-forming substrate. The heater assembly may also include a wicking element in fluid communication with at least one heating element and the liquid reservoir. Advantageously, the wicking element may ensure that the liquid aerosol-forming substrate is reliably delivered from the reservoir to the heating element.

[0020] The wicking element may be planar. The wicking element may be in the form of a sheet. The heater assembly may be planar. The heating assembly may be in the form of a sheet. The heating assembly may at least partially surround the wicking element. The wicking direction of the liquid aerosol-forming substrate within the wicking element may be parallel to the surface of at least one heating element. At least one heating element may include a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element being opposite to the second side of the wicking element. The first side may be substantially parallel to the second side. The first heating element portion may be substantially parallel to the second heating element portion.

[0021] The first heating element portion and the second heating element portion may be integral with each other. The heating element may be wrapped around the wicking element so that the heating element contacts a first side of the wicking element and a second side of the wicking element opposite the first side of the wicking element. The heating element may include one or more strips of heating material wrapped around a portion of the wicking element so that the strip substantially encloses the wrapped portion. Advantageously, this may simplify the manufacture of the heater assembly. The first heating element portion and the second heating element portion may be separate heating elements. Both the first heating element portion and the second heating element portion may be planar.

[0022] A meniscus of the liquid aerosol-forming substrate may form between the surface of the heater assembly and the at least one meniscus-forming element at room temperature.A meniscus of the liquid aerosol-forming substrate may form between the surface of the heater assembly and the at least one meniscus-forming element at standard temperature and pressure.

[0023] A meniscus of the liquid aerosol-forming substrate may be formed between the surface of the heater assembly and the at least one meniscus-forming element when the liquid aerosol-forming substrate wets the at least one meniscus-forming element with sufficient adhesion to balance the force of gravity, which will resist the formation of the meniscus depending on the orientation of the barrel and the change in surface energy that will occur when the meniscus is formed.

[0024] The at least one meniscus forming element may comprise a first meniscus forming element and a second meniscus forming element. The first meniscus forming element may contact the first heating element portion or may be spaced apart from the first heating element portion such that during use, a first meniscus of the liquid aerosol-forming substrate is formed between a surface of the first heating element portion and the first meniscus forming element. The second meniscus forming element may contact the second heating element portion or may be spaced apart from the second heating element portion such that during use, a second meniscus of the liquid aerosol-forming substrate is formed between a surface of the second heating element portion and the second meniscus forming element.

[0025] The first meniscus forming element and the second meniscus forming element may be positioned on directly opposite sides of the heater assembly. Advantageously, having two meniscus forming elements positioned on opposite sides of the heater assembly may provide enhanced mechanical support for the heater assembly. This is particularly advantageous if the two meniscus forming elements contact the heater assembly such that the two meniscus forming elements restrict deformation of the heater assembly in either direction perpendicular to the plane of the heater assembly.

[0026] The wicking element may be positioned on a first side of at least one heating element.The wicking element may be positioned on a first side of a first heating element portion.The wicking element may be positioned on a first side of a second heating element portion.

[0027] At least one meniscus forming element may be proximate to a second face of at least one heating element opposite to the first face. A first meniscus forming element may be proximate to a second face of a first heating element portion opposite to the first face of the first heating element portion. A second meniscus forming element may be proximate to a second face of a second heating element portion opposite to the first face of the second heating element portion.

[0028] Each meniscus forming element may contact the second face of at least one heating element, or may be spaced between 0 mm and 3 mm from the second face of at least one heating element. Preferably, each meniscus forming element contacts the second face of at least one heating element, or is spaced between 0 mm and 1 mm from the second face of at least one heating element.

[0029] Preferably, each meniscus forming element does not contact the second face of at least one heating element. Preferably, each meniscus forming element is spaced between 0 mm and 3 mm from the second face of at least one heating element and does not contact the second face of at least one heating element. More preferably, each meniscus forming element is spaced between 0 mm and 1 mm from the second face of at least one heating element and does not contact the second face of at least one heating element.

[0030] The first meniscus forming element and the second meniscus forming element may be adjacent to the central portion of the heater assembly. The first meniscus forming element may extend perpendicularly to the surface of the first heating element portion. The second meniscus forming element may extend perpendicularly to the surface of the second heating element portion. At least one meniscus forming element may include at least one blade. Advantageously, as disclosed below, each meniscus forming element may be easily manufactured as a blade, in particular compared to a needle. At least one blade may include a tip. At least one blade may extend perpendicularly to the surface of the heater assembly. At least one blade may extend in the longitudinal direction of the airflow passage. The tip of at least one blade may extend in the longitudinal direction of the airflow passage. Advantageously, at least one blade extending in the longitudinal direction of the airflow passage may minimize the effect on the suction resistance on the tube when the tube is connected to the aerosol generating device. At least one blade may extend between 10% and 100% of the length of the heater assembly in the longitudinal direction of the airflow passage. Preferably, at least one blade extends between 20% and 80% of the length of the heater assembly in the longitudinal direction of the airflow passage. More preferably, at least one blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage. Still more preferably, at least one vane extends across between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Even more preferably, at least one vane extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0031] At least one meniscus forming element may include at least one peripheral meniscus forming element. Each peripheral meniscus forming element in at least one peripheral meniscus forming element may be adjacent to the peripheral portion of the heater assembly. The heater assembly may include a plurality of peripheral portions, each of which is positioned adjacent to the airflow path wall. Advantageously, each peripheral meniscus forming element may also provide a liquid aerosol forming substrate of an additional volume of liquid aerosol forming substrate than already present in the wicking material in the region of the heater assembly that can be farthest from the first meniscus forming element and the second meniscus forming element. Therefore, each peripheral meniscus forming element may further provide more liquid aerosol forming substrate available at the heater assembly to evaporate during suction in the region of the heater assembly that is not yet adjacent to the meniscus forming element.

[0032] At least one peripheral meniscus forming element may comprise a first group of peripheral meniscus forming elements and a second group of peripheral meniscus forming elements. The first group of peripheral meniscus forming elements may contact the first heating element portion or may be spaced apart from the first heating element portion so that during use, a first group of menisci of the liquid aerosol forming substrate is formed between the surface of the first heating element portion and the first group of peripheral meniscus forming elements. The second group of peripheral meniscus forming elements may contact the second heating element portion or may be spaced apart from the second heating element portion so that during use, a second group of menisci of the liquid aerosol forming substrate is formed between the surface of the second heating element portion and the second group of peripheral meniscus forming elements. At least one peripheral meniscus forming element may comprise at least one peripheral meniscus forming blade. At least one peripheral meniscus forming blade may extend between 10% and 100% of the length of the heater assembly in the longitudinal direction of the airflow passage. Preferably, at least one peripheral meniscus forming blade extends between 20% and 80% of the length of the heater assembly in the longitudinal direction of the airflow passage. More preferably, at least one peripheral meniscus forming blade extends across between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage. Still more preferably, at least one peripheral meniscus forming blade extends across between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Even more preferably, at least one peripheral meniscus forming blade extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0033] At least one meniscus forming element may comprise at least one needle. The at least one needle may extend perpendicular to the longitudinal direction of the airflow passage. Advantageously, each meniscus forming element being a needle may have minimal effect on the resistance to draw on the cartridge when the cartridge is coupled to the aerosol generating device when compared to each meniscus forming element of other forms.

[0034] At least one meniscus forming element can be integrated with the airflow path wall. At least one meniscus forming element and the airflow path wall can be formed by injection molding. Advantageously, both of these features can increase the robustness of the tube and simplify the manufacture of the tube. At least one meniscus forming element and the airflow path wall can include polyetheretherketone (PEEK).

[0035] The cartridge may further comprise a mouthpiece. The mouthpiece may comprise an air outlet. The liquid reservoir may at least partially surround the airflow passage. The liquid reservoir may surround the airflow passage.

[0036] According to a second embodiment of the present disclosure, an aerosol generating system is provided, which includes a cartridge and an aerosol generating device. The cartridge may include an air inlet and an air outlet. The cartridge may include an air flow path extending between the air inlet and the air outlet. The cartridge may include a liquid reservoir, the liquid reservoir including a liquid aerosol-forming substrate. The cartridge may include a heater assembly, the heater assembly including at least one heating element in fluid communication with the air flow path. The heater assembly may be configured to heat the liquid aerosol-forming substrate supplied from the liquid reservoir to the surface of the heater assembly to generate an aerosol. The cartridge may include at least one meniscus-forming element, at least one meniscus-forming element being close to the heater assembly. Each meniscus-forming element may be positioned within the air flow path. Each meniscus-forming element may contact the surface of the heater assembly or may be spaced apart from the surface of the heater assembly so that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and at least one meniscus-forming element. The aerosol generating device may include a power supply. The power supply may be configured to supply power to the heating element. The aerosol generating device may include a control circuit system. The control circuit may be configured to control the supply of power from the power supply to the at least one heating element.The cartridge is reversibly coupled to the aerosol generating device.

[0037] The aerosol generating device may further comprise an inductor element. The at least one heating element may comprise a susceptor element configured to be inductively heated by an inductor. The inductor element may be a spiral coil. Alternatively, the inductor element may be at least one flat coil. For example, the inductor element may be two flat coils. When the cartridge is coupled to the aerosol generating device, the two flat coils may be positioned on opposite sides of the susceptor element. The inductor element may comprise copper.

[0038] When the cartridge is coupled to the aerosol generating device, the sensor element may at least partially surround the susceptor element.

[0039] The aerosol generating device may further comprise a flux concentrating element.The flux concentrating element may at least partially surround the induction element.Advantageously, the flux concentrating element may improve the efficiency of an induction apparatus comprising the induction element and the susceptor element.

[0040] Alternatively, the heating element may be configured to be resistively heated. The aerosol generating device may further include device electrical contacts. The cartridge may include cartridge electrical contacts in electrical contact with at least one heating element. When the cartridge is coupled to the aerosol generating device, the device electrical contacts and cartridge electrical contacts may be in electrical contact.

[0041] The aerosol generating device may comprise a cavity.The aerosol generating device may comprise a cavity in which at least a portion of the cartridge is located when the cartridge is coupled to the aerosol generating device.

[0042] The control circuit may further comprise a puff detector. The puff detector may be configured to be in fluid communication with the airflow path when the cartridge is coupled to the aerosol generating device. The aerosol generating system may be configured such that at least one heating element is puff-activated. Advantageously, an aerosol is thus only generated when a user puffs on the system.

[0043] The aerosol generating system may comprise a cartridge according to the first embodiment of the present disclosure.Thus, optional features of the cartridge according to the first embodiment of the present disclosure may also be present in the cartridge of the aerosol generating system according to the second embodiment of the present disclosure.

[0044] According to a third embodiment of the present disclosure, an aerosol generating device is provided. The aerosol generating device may include an air inlet and an air outlet. The aerosol generating device may include an air flow path extending between the air inlet and the air outlet. The aerosol generating device may include a liquid reservoir, which includes a liquid aerosol-forming substrate. The aerosol generating device may include a heater assembly, which includes at least one heating element in fluid communication with the air flow path. The heater assembly may be configured to heat the liquid aerosol-forming substrate supplied from the liquid reservoir to the surface of the heater assembly to generate an aerosol. The aerosol generating device may include at least one meniscus-forming element. At least one meniscus-forming element may be close to the heater assembly.

[0045] Each meniscus forming element may be positioned within the airflow pathway and may contact a surface of the heater assembly or may be spaced apart from the surface of the heater assembly such that during use a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and at least one meniscus forming element.

[0046] The aerosol generating device may comprise a power source. The power source may be configured to supply power to the heating element.

[0047] The aerosol generating device may include a control circuit system. The control circuit may be configured to control the supply of power from the power supply to the at least one heating element. The aerosol generating device may be a handheld aerosol generating device. The control circuit may further include a puff detector in fluid communication with the airflow pathway. The aerosol generating device may be configured such that the at least one heating element is actuated by puff. The aerosol generating device may include a mouthpiece. The mouthpiece may include an air outlet.

[0048] The aerosol generating device may include an inductor element. The at least one heating element may include a susceptor element configured to be inductively heated by the inductor. The inductor element may be a spiral coil. The inductor element may include copper. The inductor element may at least partially surround the susceptor element. The aerosol generating device may further include a flux concentrating element. The flux concentrating element may at least partially surround the inductor element. Alternatively, the heating element may be in electrical contact with a power source and may be configured to be resistively heated.

[0049] Each meniscus-forming element may contact the surface of the heater assembly, or may be spaced between 0 mm and 3 mm from the surface of the heater assembly. Preferably, each meniscus-forming element contacts the surface of the heater assembly, or is spaced between 0 mm and 1 mm from the surface of the heater assembly. Advantageously, such a distance from the surface of the heater assembly ensures that a meniscus can be reliably formed from the liquid aerosol-forming substrate at room temperature.

[0050] Preferably, each meniscus forming element is spaced from the surface of the heater assembly. Preferably, each meniscus forming element does not contact the surface of the heater assembly. Preferably, each meniscus forming element is spaced between 0 mm and 3 mm from the surface of the heater assembly and does not contact the surface of the heater assembly. More preferably, each meniscus forming element is spaced between 0 mm and 1 mm from the surface of at least one heating element and does not contact the surface of the heater assembly. Advantageously, each meniscus forming element spaced from the surface of the heater assembly avoids direct contact between the heater assembly and each meniscus forming element, because if the two contact, the heat from the heater assembly may damage the meniscus forming element.

[0051] Each meniscus forming element may be an elongated element. Each meniscus forming element may include a tip proximal to the heater assembly such that each tip contacts or is spaced apart from a surface of the heater assembly such that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus forming element. Advantageously, having the tip of each meniscus forming element proximal to one of the at least one heating elements ensures that sufficient surface of the heater assembly is exposed to the airflow path such that vapour can be drawn away from the heater assembly and aerosolised in the airflow path.

[0052] The airflow passage may be defined by an airflow passage wall. The airflow passage wall may include an inner surface, and at least one meniscus forming element may extend from the inner surface. Advantageously, such a feature may increase the robustness of the device and simplify manufacture of the device.

[0053] At least one heating element may include at least one mesh heating element.At least one heating element may include at least one planar heating element.A planar element may be defined as an element having a significantly greater extension in two orthogonal directions than in a third direction orthogonal to the first two directions.

[0054] Each of the at least one heating element may include a high temperature zone that reaches a maximum temperature during use, and the at least one meniscus forming element may be close to the high temperature zone. Advantageously, due to the increase in the volume of liquid present for aerosolization, the meniscus formed by each of the meniscus forming elements at the high temperature zone may locally reduce the temperature at the high temperature zone. This may ensure that the heating element does not overheat or dry out at the high temperature zone, which may lead to the production of undesirable compounds due to overheating.

[0055] The airflow path can extend in the longitudinal direction so that the direction of the airflow through the airflow path is in the longitudinal direction. The heater assembly can extend across the airflow path. Advantageously, this can provide a larger surface area for heating and evaporating the liquid aerosol-forming substrate. The heater assembly may also include a wicking element in fluid communication with at least one heating element and the liquid reservoir. Advantageously, the wicking element can ensure that the liquid aerosol-forming substrate is reliably delivered from the reservoir to the heating element.

[0056] The wicking element may be planar. The heater assembly may be planar. The wicking direction of the liquid aerosol-forming substrate within the wicking element may be parallel to the surface of the heater assembly. The at least one heating element may include a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element being opposite to the second side of the wicking element.

[0057] The first heating element portion and the second heating element portion may be integral with each other. Advantageously, this may simplify the manufacture of the heater assembly. The first heating element portion and the second heating element portion may be separate heating elements. Both the first heating element portion and the second heating element portion may be planar.

[0058] A meniscus of the liquid aerosol-forming substrate may form between the surface of the heater assembly and the at least one meniscus-forming element at room temperature.A meniscus of the liquid aerosol-forming substrate may form between the surface of the heater assembly and the at least one meniscus-forming element at standard temperature and pressure.

[0059] The at least one meniscus forming element may comprise a first meniscus forming element and a second meniscus forming element. The first meniscus forming element may contact the first heating element portion or may be spaced apart from the first heating element portion such that, during use, a first meniscus of the liquid aerosol-forming substrate is formed between a surface of the first heating element portion and the first meniscus forming element, and the second meniscus forming element may contact the second heating element portion or may be spaced apart from the second heating element portion such that, during use, a second meniscus of the liquid aerosol-forming substrate is formed between a surface of the second heating element portion and the second meniscus forming element.

[0060] The first meniscus forming element and the second meniscus forming element may be positioned on directly opposite sides of the heater assembly. Advantageously, having two meniscus forming elements positioned on opposite sides of the heater assembly may provide enhanced mechanical support for the heater assembly. This is particularly advantageous if the two meniscus forming elements contact the heater assembly such that the two meniscus forming elements may restrict deformation of the heater assembly in either direction perpendicular to the plane of the heater assembly.

[0061] The first meniscus forming element and the second meniscus forming element may be adjacent to the central portion of the heater assembly. The first meniscus forming element may extend perpendicular to the surface of the first heating element portion, and the second meniscus forming element may extend perpendicular to the surface of the second heating element portion. At least one meniscus forming element may include at least one blade. Advantageously, as disclosed below, each meniscus forming element may be easier to manufacture as a blade, in particular compared to a needle. At least one blade may include a tip. At least one blade may extend perpendicular to the surface of the heater assembly. At least one blade may extend in the longitudinal direction of the airflow passage. The tip of at least one blade may extend in the longitudinal direction of the airflow passage. Advantageously, at least one blade extending in the longitudinal direction of the airflow passage may minimize the effect on the suction resistance on the device. At least one blade may extend between 10% and 100% of the length of the heater assembly in the longitudinal direction of the airflow passage. Preferably, at least one blade extends between 20% and 80% of the length of the heater assembly in the longitudinal direction of the airflow passage. More preferably, at least one blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage. Still more preferably, at least one vane extends across between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Even more preferably, at least one vane extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0062] At least one meniscus forming element may include at least one peripheral meniscus forming element. Each of the at least one peripheral meniscus forming element may be adjacent to a peripheral portion of a plurality of peripheral portions of the heater assembly, each of the peripheral portions of the heater assembly being positioned adjacent to the airflow path wall. Advantageously, each peripheral meniscus forming element may also provide an additional volume of liquid aerosol-forming substrate than the liquid aerosol-forming substrate already present in the wicking material in the area of ​​the heater assembly that may be farthest from the first meniscus forming element and the second meniscus forming element. Therefore, each peripheral meniscus forming element may further provide more liquid aerosol-forming substrate available at the heater assembly to evaporate during suction in an area of ​​the heater assembly that is not yet adjacent to the meniscus forming element.

[0063] The at least one peripheral meniscus forming element may comprise a first set of peripheral meniscus forming elements and a second set of peripheral meniscus forming elements. The first set of peripheral meniscus forming elements may contact the first heating element portion or may be spaced apart from the first heating element portion such that during use, a first set of menisci of the liquid aerosol-forming substrate is formed between the surface of the first heating element portion and the first set of peripheral meniscus forming elements, and the second set of peripheral meniscus forming elements may contact the second heating element portion or may be spaced apart from the second heating element portion such that during use, a second set of menisci of the liquid aerosol-forming substrate is formed between the surface of the second heating element portion and the second set of peripheral meniscus forming elements. The at least one peripheral meniscus forming blade may extend between 10% and 100% of the length of the heater assembly in the longitudinal direction of the airflow passage. Preferably, the at least one peripheral meniscus forming blade extends between 20% and 80% of the length of the heater assembly in the longitudinal direction of the airflow passage. More preferably, the at least one peripheral meniscus forming blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage. Still more preferably, at least one peripheral meniscus forming blade extends across between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Even more preferably, at least one peripheral meniscus forming blade extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0064] At least one meniscus forming element may comprise at least one needle. The at least one needle may extend perpendicular to the longitudinal direction of the airflow passage. Advantageously, each meniscus forming element being a needle may have minimal effect on the resistance to draw on the aerosol generating device when compared to other forms of each meniscus forming element.

[0065] At least one meniscus forming element may be integral with the airflow passage wall. The at least one meniscus forming element and the airflow passage wall may be formed by injection molding. Advantageously, both of these features may increase the robustness of the device and simplify the manufacture of the device. The at least one meniscus forming element and the airflow passage wall may comprise polyetheretherketone (PEEK).

[0066] The liquid reservoir may at least partially surround the airflow passageway.The liquid reservoir may surround the airflow passageway.

[0067] 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.

[0068] Example Ex1: A cartridge for an aerosol generating system, the cartridge comprising:

[0069] air inlet and air outlet;

[0070] an air flow passage extending between the air inlet and the air outlet;

[0071] a liquid reservoir comprising a liquid aerosol-forming substrate;

[0072] a heater assembly comprising at least one heating element in fluid communication with the airflow passageway, the heater assembly being configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; and

[0073] at least one meniscus-forming element, the at least one meniscus-forming element being proximate to the heater assembly;

[0074] Each meniscus forming element is positioned within the airflow passage and contacts or is spaced apart from a surface of the heater assembly such that during use a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus forming element.

[0075] Example Ex2: A cartridge according to Example Ex1, wherein each meniscus-forming element contacts the surface of the heater assembly or is spaced between 0 mm and 3 mm from the surface of the heater assembly.

[0076] Example Ex3: A cartridge according to Example Ex2, wherein each meniscus-forming element contacts the surface of the heater assembly or is spaced between 0 mm and 1 mm from the surface of the heater assembly.

[0077] Example Ex4: A tube according to any of the preceding examples, wherein each meniscus forming element is an elongated element.

[0078] Example Ex5: A cartridge according to any of the preceding examples, wherein each meniscus forming element comprises a tip close to the heater assembly, such that each tip contacts the surface of the heater assembly or is spaced apart from the surface of the heater assembly, such that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus forming element.

[0079] Example Ex6: A cartridge according to any of the preceding examples, wherein the airflow pathway is defined by an airflow pathway wall, and wherein the airflow pathway wall comprises an inner surface, and wherein the at least one meniscus-forming element extends from the inner surface.

[0080] Example Ex7: A cartridge according to any preceding example, wherein the at least one heating element comprises a susceptor element configured to be inductively heated.

[0081] Example Ex8: A cartridge according to any one of Examples Ex1 to Ex6, wherein the at least one heating element is configured to be resistively heated.

[0082] Example Ex9: A cartridge according to any of the preceding examples, wherein the at least one heating element comprises at least one mesh heating element.

[0083] Example Ex10: A cartridge according to any of the preceding examples, wherein the at least one heating element comprises at least one planar heating element.

[0084] Example Ex11: A cartridge according to any of the preceding examples, wherein each of the at least one heating element comprises a high temperature zone which reaches a maximum temperature during use, and wherein the at least one meniscus forming element is close to the high temperature zone.

[0085] Example Ex12: A cartridge according to any of the preceding examples, wherein the airflow passage extends in a longitudinal direction such that the direction of the airflow passing through the airflow passage is in the longitudinal direction.

[0086] Example Ex13: A cartridge according to Example Ex12, wherein the heater assembly extends across the airflow passage.

[0087] Example Ex14: A cartridge according to Example Ex12 or Ex13, wherein the heater assembly further comprises a wicking element in fluid communication with the at least one heating element and the liquid reservoir.

[0088] Example Ex15: A tube according to Example Ex14, wherein the wicking element is planar.

[0089] Example Ex16: A cartridge according to Example Ex15, wherein the heater assembly is planar.

[0090] Example Ex17: A cartridge according to Example Ex16, wherein the wicking direction of the liquid aerosol-forming matrix within the wicking element is parallel to the surface of the heater assembly.

[0091] Example Ex18: A tube according to any one of Examples Ex14 to Ex17, wherein the at least one heating element includes a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element being opposite to the second side of the wicking element.

[0092] Example Ex19: A cartridge according to Example Ex18, wherein the first heating element portion and the second heating element portion are integral with each other.

[0093] Example Ex20: A cartridge according to Example Ex18, wherein the first heating element portion and the second heating element portion are separate heating elements.

[0094] Example Ex21: A cartridge according to any one of Examples Ex18 to Ex20, wherein both the first heating element portion and the second heating element portion are planar.

[0095] Example Ex22: A barrel according to any one of Examples Ex18 to Ex21, wherein the at least one meniscus forming element comprises a first meniscus forming element and a second meniscus forming element.

[0096] Example Ex23: A cartridge according to Example Ex22, wherein the first meniscus-forming element contacts the first heating element portion or is spaced apart from the first heating element portion, such that during use, a first meniscus of the liquid aerosol-forming substrate is formed between a surface of the first heating element portion and the first meniscus-forming element, and the second meniscus-forming element contacts the second heating element portion or is spaced apart from the second heating element portion, such that during use, a second meniscus of the liquid aerosol-forming substrate is formed between a surface of the second heating element portion and the second meniscus-forming element.

[0097] Example Ex24: A cartridge according to Example Ex22 or Ex23, wherein the first meniscus-forming element and the second meniscus-forming element are positioned on directly opposite sides of the heater assembly.

[0098] Example Ex25: A cartridge according to any one of Examples Ex22 to Ex24, wherein the first meniscus-forming element and the second meniscus-forming element are adjacent to a central portion of the heater assembly.

[0099] Example Ex26: A cartridge according to any one of Examples Ex22 to Ex25, wherein the first meniscus-forming element extends perpendicularly to a surface of the first heating element portion, and the second meniscus-forming element extends perpendicularly to a surface of the second heating element portion.

[0100] Example Ex27: A barrel according to any one of Examples Ex12 to Ex26, wherein the at least one meniscus forming element comprises at least one blade, and the at least one blade comprises a tip.

[0101] Example Ex28: A barrel according to Example Ex27, wherein the at least one blade extends perpendicular to the surface of the heater assembly.

[0102] Example Ex29: A barrel according to Example Ex27 or Ex28, wherein the at least one blade extends in the longitudinal direction of the air flow passage.

[0103] Example Ex30: A barrel according to Example Ex29, wherein the tip of the at least one blade extends in the longitudinal direction of the airflow passage.

[0104] Example Ex31: A cartridge according to Example Ex29 or Ex30, wherein the at least one blade extends between 10% and 100% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0105] Example Ex32: A cartridge according to Example Ex31, wherein the at least one blade extends between 20% and 80% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0106] Example Ex33: A cartridge according to Example Ex32, wherein the at least one blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0107] Example Ex34: A cartridge according to Example Ex33, wherein the at least one blade extends between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0108] Example Ex35: A cartridge according to Example Ex34, wherein the at least one blade extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0109] Example Ex36: A tube according to any one of Examples Ex12 to Ex35, wherein the at least one meniscus forming element comprises at least one peripheral meniscus forming element.

[0110] Example Ex37: A barrel according to Example Ex36, wherein each of the at least one peripheral meniscus forming element is adjacent to one of the plurality of peripheral portions of the heater assembly, and each of the peripheral portions of the heater assembly is positioned adjacent to the airflow passage wall.

[0111] Example Ex38: A barrel according to Example Ex36 or Ex37, wherein the at least one peripheral meniscus forming element comprises a first group of peripheral meniscus forming elements and a second group of peripheral meniscus forming elements.

[0112] Example Ex39: A cartridge according to Example Ex38, when subordinate to Example Ex18, wherein the first group of peripheral meniscus forming elements contacts the first heating element portion or is spaced apart from the first heating element portion, so that during use, a first group of menisci of the liquid aerosol forming substrate is formed between the surface of the first heating element portion and the first group of peripheral meniscus forming elements, and the second group of peripheral meniscus forming elements contacts the second heating element portion or is spaced apart from the second heating element portion, so that during use, a second group of menisci of the liquid aerosol forming substrate is formed between the surface of the second heating element portion and the second group of peripheral meniscus forming elements.

[0113] Example Ex40: A barrel according to any one of Examples Ex36 to Ex39, wherein the at least one peripheral meniscus forming element includes at least one peripheral meniscus forming blade, and wherein the at least one peripheral meniscus forming blade extends between 20% and 80% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0114] Example Ex41: A cartridge according to Example E40, wherein the at least one peripheral meniscus-forming blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0115] Example Ex42: A cartridge according to Example Ex41, wherein the at least one peripheral meniscus-forming blade extends between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0116] Example Ex43: A cartridge according to Example Ex42, wherein the at least one peripheral meniscus-forming blade extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0117] Example Ex44: A tube according to any one of Examples Ex12 to Ex43, wherein the at least one meniscus forming element comprises at least one needle.

[0118] Example Ex45: A cartridge according to Example Ex44, wherein the at least one needle extends perpendicular to the longitudinal direction of the airflow passage.

[0119] Example Ex46: A cartridge according to any of the preceding examples, wherein the at least one meniscus forming element is integral with the airflow passage wall.

[0120] Example Ex47: A barrel according to Example Ex46, wherein the at least one meniscus forming element and the airflow passage wall are formed by injection molding.

[0121] Example Ex48: A barrel according to any of the preceding examples, wherein the at least one meniscus forming element and the airflow passage wall comprise polyetheretherketone (PEEK).

[0122] Example Ex49: A cartridge according to any of the preceding examples, further comprising a mouthpiece, wherein the mouthpiece comprises the air outlet.

[0123] Example Ex50: A cartridge according to any of the preceding examples, wherein the liquid reservoir surrounds the air flow passage.

[0124] Example Ex51: An aerosol generating system, comprising a cartridge, the cartridge comprising:

[0125] air inlet and air outlet;

[0126] an air flow passage extending between the air inlet and the air outlet;

[0127] a liquid reservoir comprising a liquid aerosol-forming substrate;

[0128] a heater assembly comprising at least one heating element in fluid communication with the airflow passageway, the heater assembly being configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; and

[0129] at least one meniscus-forming element, the at least one meniscus-forming element being proximate to the heater assembly;

[0130] wherein each meniscus-forming element is positioned within the airflow passageway and contacts or is spaced apart from a surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus-forming element; and

[0131] An aerosol generating device, the aerosol generating device comprising:

[0132] a power source configured to supply power to the heating element; and

[0133] a control circuit configured to control the supply of power from the power source to the at least one heating element;

[0134] Wherein the cartridge is reversibly coupled to the aerosol generating device.

[0135] Example Ex52: An aerosol generating system according to Example Ex51, wherein the aerosol generating device further comprises an inductor element, and the at least one heating element comprises a susceptor element configured to be inductively heated by the inductor.

[0136] Example Ex53: An aerosol generating system according to Example Ex52, wherein the sensor element is a spiral coil.

[0137] Example Ex54: An aerosol generating system according to Example Ex52 or Ex53, wherein the sensor element comprises copper.

[0138] Example Ex55: An aerosol generating system according to any one of Examples Ex52 to Ex54, wherein when the cartridge is coupled to the aerosol generating device, the sensor element at least partially surrounds the receptor element.

[0139] Example Ex56: An aerosol generating system according to Example Ex55, wherein the aerosol generating device further comprises a flux concentrating element, which at least partially surrounds the sensor element.

[0140] Example Ex57: An aerosol generating system according to Example Ex51, wherein the heating element is configured to be resistively heated, and wherein the aerosol generating device also includes a device electrical contact, and the tube includes a tube electrical contact that is in electrical contact with the at least one heating element, so that when the tube is connected to the aerosol generating device, the device electrical contact and the tube electrical contact are in electrical contact.

[0141] Example Ex58: An aerosol generating system according to any one of Examples Ex51 to Ex57, wherein the aerosol generating device comprises a cavity, and when the tube is connected to the aerosol generating device, at least a portion of the tube is located in the cavity.

[0142] Example Ex59: An aerosol generating system according to any one of Examples Ex51 to Ex58, wherein the control circuit further comprises a puff detector, the puff detector being configured to be connected to the airflow pathway fluid when the cartridge is connected to the aerosol generating device, and the aerosol generating system being configured such that the at least one heating element is actuated by puff.

[0143] Example Ex60: An aerosol generating system according to any one of Examples Ex51 to Ex59, wherein each meniscus-forming element contacts the surface of the heater assembly or is spaced between 0 mm and 3 mm from the surface of the heater assembly.

[0144] Example Ex61: An aerosol generating system according to Example Ex60, wherein each meniscus-forming element contacts the surface of the heater assembly or is spaced between 0 mm and 1 mm from the surface of the heater assembly.

[0145] Example Ex62: An aerosol generating system according to any one of Examples Ex51 to Ex61, wherein each meniscus forming element is an elongated element.

[0146] Example Ex63: An aerosol generating system according to any one of Examples Ex51 to Ex62, wherein each meniscus forming element includes a tip close to the heater assembly, so that each tip contacts the surface of the heater assembly or is spaced apart from the surface of the heater assembly, so that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus forming element.

[0147] Example Ex64: An aerosol generating system according to any one of Examples Ex51 to Ex63, wherein the airflow pathway is defined by an airflow pathway wall, and wherein the airflow pathway wall includes an inner surface, and wherein the at least one meniscus forming element extends from the inner surface.

[0148] Example Ex65: An aerosol generating system according to any one of Examples Ex51 to Ex64, wherein the at least one heating element comprises at least one mesh heating element.

[0149] Example Ex66: An aerosol generating system according to any one of Examples Ex51 to Ex65, wherein the at least one heating element comprises at least one planar heating element.

[0150] Example Ex67: An aerosol generating system according to any one of Examples Ex51 to Ex66, wherein each of the at least one heating element comprises a high temperature zone which reaches a maximum temperature during use, and the at least one meniscus forming element is close to the high temperature zone.

[0151] Example Ex68: An aerosol generating system according to any one of Examples Ex51 to Ex67, wherein the airflow passage extends in a longitudinal direction so that the direction of the airflow passing through the airflow passage is in the longitudinal direction.

[0152] Example Ex69: An aerosol generating system according to Example Ex68, wherein the heater assembly extends across the airflow path.

[0153] Example Ex70: An aerosol generating system according to Example Ex68 or Ex69, wherein the heater assembly further comprises a wicking element in fluid communication with the at least one heating element and the liquid reservoir.

[0154] Example Ex71: An aerosol generating system according to Example Ex70, wherein the wicking element is planar.

[0155] Example Ex72: An aerosol generating system according to Example Ex71, wherein the heater assembly is planar.

[0156] Example Ex73: An aerosol generating system according to Example Ex72, wherein the wicking direction of the liquid aerosol-forming substrate within the wicking element is parallel to the surface of the heater assembly.

[0157] Example Ex74: An aerosol generating system according to any one of Examples Ex71 to Ex73, wherein the at least one heating element includes a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element being opposite to the second side of the wicking element.

[0158] Example Ex75: An aerosol generating system according to Example Ex74, wherein the first heating element portion and the second heating element portion are integral with each other.

[0159] Example Ex76: An aerosol generating system according to Example Ex74, wherein the first heating element portion and the second heating element portion are separate heating elements.

[0160] Example Ex77: An aerosol generating system according to any one of Examples Ex74 to Ex76, wherein both the first heating element portion and the second heating element portion are planar.

[0161] Example Ex78: An aerosol generating system according to any one of Examples Ex74 to Ex77, wherein the at least one meniscus forming element comprises a first meniscus forming element and a second meniscus forming element.

[0162] Example Ex79: An aerosol generating system according to Example Ex78, wherein the first meniscus forming element contacts the first heating element portion or is spaced apart from the first heating element portion, so that during use, a first meniscus of the liquid aerosol forming substrate is formed between the surface of the first heating element portion and the first meniscus forming element, and the second meniscus forming element contacts the second heating element portion or is spaced apart from the second heating element portion, so that during use, a second meniscus of the liquid aerosol forming substrate is formed between the surface of the second heating element portion and the second meniscus forming element.

[0163] Example Ex80: An aerosol generating system according to Example Ex78 or Ex79, wherein the first meniscus forming element and the second meniscus forming element are positioned on directly opposite sides of the heater assembly.

[0164] Example Ex81: An aerosol generating system according to any one of Examples Ex78 to Ex80, wherein the first meniscus forming element and the second meniscus forming element are adjacent to a central portion of the heater assembly.

[0165] Example Ex82: An aerosol generating system according to any one of Examples Ex78 to Ex81, wherein the first meniscus forming element extends perpendicular to the surface of the first heating element portion, and the second meniscus forming element extends perpendicular to the surface of the second heating element portion.

[0166] Example Ex83: An aerosol generating system according to any one of Examples Ex68 to Ex82, wherein the at least one meniscus forming element comprises at least one blade, and the at least one blade comprises a tip.

[0167] Example Ex84: An aerosol generating system according to Example Ex83, wherein the at least one blade extends perpendicular to the surface of the heater assembly.

[0168] Example Ex85: An aerosol generating system according to Example Ex83 or Ex84, wherein the at least one blade extends in the longitudinal direction of the airflow passage.

[0169] Example Ex86: An aerosol generating system according to Example Ex85, wherein the tip of the at least one blade extends in the longitudinal direction of the airflow passage.

[0170] Example Ex87: An aerosol generating system according to Example Ex85 or Ex86, wherein the at least one blade extends between 10% and 100% of the length of the heater assembly in the longitudinal direction of the airflow pathway.

[0171] Example Ex88: An aerosol generating system according to Example Ex87, wherein the at least one blade extends between 20% and 80% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0172] Example Ex89: An aerosol generating system according to Example Ex88, wherein the at least one blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0173] Example Ex90: An aerosol generating system according to Example Ex89, wherein the at least one blade extends between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0174] Example Ex91: An aerosol generating system according to Example Ex90, wherein the at least one blade extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0175] Example Ex92: An aerosol generating system according to any one of Examples Ex68 to Ex91, wherein the at least one meniscus forming element comprises at least one peripheral meniscus forming element.

[0176] Example Ex93: An aerosol generating system according to Example Ex92, wherein each of the at least one peripheral meniscus forming element is adjacent to one of the plurality of peripheral portions of the heater assembly, and each of the peripheral portions of the heater assembly is positioned adjacent to the airflow path wall.

[0177] Example Ex94: An aerosol generating system according to Example Ex92 or Ex93, wherein the at least one peripheral meniscus forming element comprises a first group of peripheral meniscus forming elements and a second group of peripheral meniscus forming elements.

[0178] Example Ex95: An aerosol generating system according to Example Ex94, when subordinate to Example Ex18, wherein the first group of peripheral meniscus forming elements contacts the first heating element part or is separated from the first heating element part, so that during use, a first group of menisci of the liquid aerosol forming substrate is formed between the surface of the first heating element part and the first group of peripheral meniscus forming elements, and the second group of peripheral meniscus forming elements contacts the second heating element part or is separated from the second heating element part, so that during use, a second group of menisci of the liquid aerosol forming substrate is formed between the surface of the second heating element part and the second group of peripheral meniscus forming elements.

[0179] Example Ex96: An aerosol generating system according to any one of Examples Ex92 to Ex95, wherein the at least one peripheral meniscus forming element includes at least one peripheral meniscus forming blade, and wherein the at least one peripheral meniscus forming blade extends across 20% to 80% of the length of the heater assembly in the longitudinal direction of the airflow path.

[0180] Example Ex97: An aerosol generating system according to Example Ex96, wherein the at least one peripheral meniscus-forming blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0181] Example Ex98: An aerosol generating system according to Example Ex97, wherein the at least one peripheral meniscus-forming blade extends between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0182] Example Ex99: An aerosol generating system according to Example Ex98, wherein the at least one peripheral meniscus-forming blade extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0183] Example Ex100: An aerosol generating system according to any one of Examples Ex68 to Ex99, wherein the at least one meniscus forming element comprises at least one needle.

[0184] Example Ex101: An aerosol generating system according to Example Ex100, wherein the at least one needle extends perpendicular to the longitudinal direction of the airflow passage.

[0185] Example Ex102: An aerosol generating system according to any one of Examples Ex51 to Ex101, wherein the at least one meniscus forming element is integral with the airflow passage wall.

[0186] Example Ex103: An aerosol generating system according to Example Ex102, wherein the at least one meniscus forming element and the airflow passage wall are formed by injection molding.

[0187] Example Ex104: An aerosol generating system according to any one of Examples Ex51 to Ex103, wherein the at least one meniscus forming element and the airflow passage wall comprise polyetheretherketone (PEEK).

[0188] Example Ex105: An aerosol generating system according to any one of Examples Ex51 to Ex104, further comprising a mouthpiece, wherein the mouthpiece comprises the air outlet.

[0189] Example Ex106: An aerosol generating system according to any one of Examples Ex51 to Ex105, wherein the liquid reservoir surrounds the airflow passage.

[0190] Example Ex107: An aerosol generating device, the aerosol generating device comprising:

[0191] air inlet and air outlet;

[0192] an air flow passage extending between the air inlet and the air outlet;

[0193] a liquid reservoir comprising a liquid aerosol-forming substrate;

[0194] a heater assembly comprising at least one heating element in fluid communication with the airflow passageway, the heater assembly being configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; and

[0195] at least one meniscus-forming element, the at least one meniscus-forming element being proximate to the heater assembly;

[0196] wherein each meniscus-forming element is positioned within the airflow passageway and in contact with or spaced from a surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus-forming element;

[0197] a power source configured to supply power to the heating element; and

[0198] A control circuit is configured to control the supply of power from the power source to the at least one heating element.

[0199] Example Ex108: An aerosol generating device according to Example Ex107, wherein the aerosol generating device is a handheld aerosol generating device.

[0200] Example Ex109: An aerosol generating device according to Example Ex107 or Ex108, wherein the control circuit further comprises a puff detector connected to the airflow passage fluid, and the aerosol generating device is configured such that the at least one heating element is actuated by puff.

[0201] Example Ex110: An aerosol generating device according to any one of Examples Ex107 to Ex109, further comprising a mouthpiece, and wherein the mouthpiece comprises the air outlet.

[0202] Example Ex111: The aerosol generating device according to any one of Examples Ex107 to Ex110 further includes a sensor element, and the at least one heating element includes a susceptor element configured to be inductively heated by the sensor.

[0203] Example Ex112: An aerosol generating device according to Example Ex111, wherein the sensor element is a spiral coil.

[0204] Example Ex113: An aerosol generating device according to Example Ex111 or Ex112, wherein the sensor element comprises copper.

[0205] Example Ex114: An aerosol generating device according to any one of Examples Ex111 to Ex113, wherein the sensor element at least partially surrounds the receptor element.

[0206] Example Ex115: The aerosol generating device according to Example Ex114 further includes a flux concentrating element, which at least partially surrounds the sensor element.

[0207] Example Ex116: An aerosol generating device according to any one of Examples Ex107 to Ex110, wherein the heating element is in electrical contact with the power source and is configured to be resistively heated.

[0208] Example Ex117: An aerosol generating device according to any one of Examples Ex107 to Ex116, wherein each meniscus forming element contacts the surface of the heater assembly or is spaced between 0 mm and 3 mm from the surface of the heater assembly.

[0209] Example Ex118: An aerosol generating device according to Example Ex117, wherein each meniscus forming element contacts the surface of the heater assembly or is spaced between 0 mm and 1 mm from the surface of the heater assembly.

[0210] Example Ex119: An aerosol generating device according to any one of Examples Ex107 to Ex118, wherein each meniscus forming element is an elongated element.

[0211] Example Ex120: An aerosol generating device according to any one of Examples Ex107 to Ex119, wherein each meniscus forming element includes a tip close to the heater assembly, so that each tip contacts the surface of the heater assembly or is spaced apart from the surface of the heater assembly, so that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus forming element.

[0212] Example Ex121: An aerosol generating device according to any one of Examples Ex107 to Ex120, wherein the airflow pathway is defined by an airflow pathway wall, and wherein the airflow pathway wall includes an inner surface, and wherein the at least one meniscus forming element extends from the inner surface.

[0213] Example Ex122: An aerosol generating device according to any one of Examples Ex107 to Ex121, wherein the at least one heating element comprises at least one mesh heating element.

[0214] Example Ex123: An aerosol generating device according to any one of Examples Ex107 to Ex122, wherein the at least one heating element comprises at least one planar heating element.

[0215] Example Ex124: An aerosol generating device according to any one of Examples Ex107 to Ex123, wherein each of the at least one heating element includes a high temperature zone, which reaches a maximum temperature during use, and the at least one meniscus forming element is close to the high temperature zone.

[0216] Example Ex125: An aerosol generating device according to any one of Examples Ex107 to Ex124, wherein the airflow passage extends in a longitudinal direction so that the direction of the airflow passing through the airflow passage is in the longitudinal direction.

[0217] Example Ex126: An aerosol generating device according to Example Ex125, wherein the heater assembly extends across the airflow path.

[0218] Example Ex127: An aerosol generating device according to Example Ex125 or Ex126, wherein the heater assembly further comprises a wicking element in fluid communication with the at least one heating element and the liquid reservoir.

[0219] Example Ex128: An aerosol generating device according to Example Ex127, wherein the wicking element is planar.

[0220] Example Ex129: An aerosol generating device according to Example Ex128, wherein the heater assembly is planar.

[0221] Example Ex130: An aerosol generating device according to Example Ex129, wherein the wicking direction of the liquid aerosol-forming substrate in the wicking element is parallel to the surface of the heater assembly.

[0222] Example Ex131: An aerosol generating device according to any one of Examples E128 to Ex130, wherein the at least one heating element includes a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element being opposite to the second side of the wicking element.

[0223] Example Ex132: An aerosol generating device according to Example Ex131, wherein the first heating element portion and the second heating element portion are integral with each other.

[0224] Example Ex133: An aerosol generating device according to Example Ex132, wherein the first heating element portion and the second heating element portion are separate heating elements.

[0225] Example Ex134: An aerosol generating device according to any one of Examples Ex131 to Ex133, wherein both the first heating element portion and the second heating element portion are planar.

[0226] Example Ex135: An aerosol generating device according to any one of Examples Ex131 to Ex134, wherein the at least one meniscus forming element comprises a first meniscus forming element and a second meniscus forming element.

[0227] Example Ex136: An aerosol generating device according to Example Ex135, wherein the first meniscus forming element contacts the first heating element portion or is separated from the first heating element portion, so that during use, a first meniscus of the liquid aerosol forming substrate is formed between the surface of the first heating element portion and the first meniscus forming element, and the second meniscus forming element contacts the second heating element portion or is separated from the second heating element portion, so that during use, a second meniscus of the liquid aerosol forming substrate is formed between the surface of the second heating element portion and the second meniscus forming element.

[0228] Example Ex137: An aerosol generating device according to Example Ex135 or Ex136, wherein the first meniscus forming element and the second meniscus forming element are positioned on directly opposite sides of the heater assembly.

[0229] Example Ex138: An aerosol generating device according to any one of Examples Ex135 to Ex137, wherein the first meniscus forming element and the second meniscus forming element are adjacent to a central portion of the heater assembly.

[0230] Example Ex139: An aerosol generating device according to any one of Examples Ex135 to Ex138, wherein the first meniscus forming element extends perpendicularly to the surface of the first heating element portion, and the second meniscus forming element extends perpendicularly to the surface of the second heating element portion.

[0231] Example Ex140: An aerosol generating device according to any one of Examples Ex125 to Ex139, wherein the at least one meniscus forming element comprises at least one blade, and the at least one blade comprises a tip.

[0232] Example Ex141: An aerosol generating device according to Example Ex140, wherein the at least one blade extends perpendicular to the surface of the heater assembly.

[0233] Example Ex142: An aerosol generating device according to Example Ex140 or Ex141, wherein the at least one blade extends in the longitudinal direction of the airflow passage.

[0234] Example Ex143: An aerosol generating device according to Example Ex142, wherein the tip of the at least one blade extends in the longitudinal direction of the airflow passage.

[0235] Example Ex144: An aerosol generating device according to Example Ex142 or Ex143, wherein the at least one blade extends between 10% and 100% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0236] Example Ex145: An aerosol generating device according to Example Ex144, wherein the at least one blade extends between 20% and 80% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0237] Example Ex146: An aerosol generating device according to Example Ex145, wherein the at least one blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0238] Example Ex147: An aerosol generating device according to Example Ex146, wherein the at least one blade extends between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0239] Example Ex148: An aerosol generating device according to Example Ex147, wherein the at least one blade extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0240] Example Ex149: An aerosol generating device according to any one of Examples Ex125 to Ex148, wherein the at least one meniscus forming element comprises at least one peripheral meniscus forming element.

[0241] Example Ex150: An aerosol generating device according to Example Ex149, wherein each of the at least one peripheral meniscus forming element is adjacent to one of the plurality of peripheral portions of the heater assembly, and each of the peripheral portions of the heater assembly is positioned adjacent to the airflow path wall.

[0242] Example Ex151: An aerosol generating device according to example Ex149 or Ex150, wherein the at least one peripheral meniscus forming element comprises a first group of peripheral meniscus forming elements and a second group of peripheral meniscus forming elements.

[0243] Example Ex152: An aerosol generating device according to Example Ex151, when subordinate to Example Ex18, wherein the first group of peripheral meniscus forming elements contacts the first heating element part or is separated from the first heating element part, so that during use, the first group of menisci of the liquid aerosol forming substrate is formed between the surface of the first heating element part and the first group of peripheral meniscus forming elements, and the second group of peripheral meniscus forming elements contacts the second heating element part or is separated from the second heating element part, so that during use, the second group of menisci of the liquid aerosol forming substrate is formed between the surface of the second heating element part and the second group of peripheral meniscus forming elements.

[0244] Example Ex153: An aerosol generating device according to any one of Examples Ex149 to Ex152, wherein the at least one peripheral meniscus forming element includes at least one peripheral meniscus forming blade, and wherein the at least one peripheral meniscus forming blade extends across 20% to 80% of the length of the heater assembly in the longitudinal direction of the airflow path.

[0245] Example Ex154: An aerosol generating device according to Example Ex153, wherein the at least one peripheral meniscus-forming blade extends between 30% and 70% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0246] Example Ex155: An aerosol generating device according to Example Ex154, wherein the at least one peripheral meniscus-forming blade extends between 40% and 60% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0247] Example Ex156: An aerosol generating device according to Example Ex155, wherein the at least one peripheral meniscus-forming blade extends across approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0248] Example Ex157: An aerosol generating device according to any one of Examples Ex125 to Ex156, wherein the at least one meniscus forming element comprises at least one needle.

[0249] Example Ex158: An aerosol generating device according to Example Ex157, wherein the at least one needle extends perpendicular to the longitudinal direction of the airflow passage.

[0250] Example Ex159: An aerosol generating device according to any one of Examples Ex107 to Ex158, wherein the at least one meniscus forming element is integral with the airflow passage wall.

[0251] Example Ex160: An aerosol generating device according to Example Ex159, wherein the at least one meniscus forming element and the airflow passage wall are formed by injection molding.

[0252] Example Ex161: An aerosol generating device according to any one of Examples Ex107 to Ex160, wherein the at least one meniscus forming element and the airflow passage wall comprise polyetheretherketone (PEEK).

[0253] Example Ex162: An aerosol generating device according to any one of Examples Ex170 to Ex161, wherein the liquid reservoir surrounds the airflow passage.

[0254] Features of one embodiment of the invention may be applicable to other aspects of the invention.

[0255] Several examples will now be further described with reference to the accompanying drawings, in which:

[0256] Figure 1A a schematic diagram showing a cross-section of a cartridge for an aerosol generating system according to a first embodiment of the present disclosure, the cartridge comprising a heater holder;

[0257] Figure 1B Shows Figure 1A Schematic diagram of alternative cross-sections of a barrel;

[0258] Figure 2 Shows Figure 1A and 1B A schematic diagram of another alternative cross-section of a barrel;

[0259] Figure 3Aa schematic diagram showing a cross-section of an aerosol generating system according to a second embodiment of the present disclosure, wherein the cartridge is separated from the aerosol generating device;

[0260] Figure 3B a schematic diagram showing a cross-section of an aerosol generating system according to a second embodiment of the present disclosure, wherein a cartridge is coupled to an aerosol generating device;

[0261] Figure 4 A schematic diagram showing a cross-section of an aerosol generating device according to a third embodiment of the present disclosure.

[0262] Figure 1A and Figure 1B A schematic diagram of two cross sections of a cartridge 10 for an aerosol generating system according to a first embodiment of the present disclosure is shown. The two cross sections are taken in two planes perpendicular to each other.

[0263] The cartridge 10 includes a heater holder 14 and a heater assembly 12 mounted in the heater holder 14. The heater assembly 12 is planar and thin, having a thickness dimension that is substantially smaller than the length dimension and the width dimension. The heater assembly 12 is shaped in a rectangular form and includes three layers: a first susceptor element 16, a second susceptor element 18, and a wicking element 20 disposed between the first susceptor element 16 and the second susceptor element 18. Each of the first susceptor element 16, the second susceptor element 18, and the wicking element 20 is generally formed in a rectangular shape, and each susceptor element has the same length and width dimensions, and the width of the susceptor elements 16, 18 is less than the width of the wicking element 20. Therefore, the wicking element 20 includes an outer exposed portion of the wicking element, each of which protrudes into one of the two channels 45. The first susceptor element 16 and the second susceptor element 18 are substantially identical and include a sintered mesh formed of stainless steel wire (e.g., ferritic stainless steel wire or austenitic stainless steel wire). The wicking element 20 includes a porous body of rayon. The wicking element 20 is configured to deliver liquid from an externally exposed surface of the wicking element 20 to the first susceptor element 16 and the second susceptor element 18 .

[0264] Each of the first susceptor element 16 and the second susceptor element 18 is configured to be heatable by penetration with an alternating magnetic field for vaporizing the aerosol-forming substrate. The wicking element 20 contacts the heater holder 14 such that the heater holder 14 supports the heater assembly 12 in place in the cartridge 10 .

[0265] The heater assembly 12 is partially disposed within the interior passage 26 of the tubular heater holder 14 and extends in a plane parallel to the central longitudinal axis of the heater holder 14. The first susceptor element 16 and the second susceptor element 18 are completely disposed within the interior passage 26 of the heater holder 14, and the wicking element extends through the opening 28 in the side wall of the heater holder 14 into one of the two channels 45.

[0266] The barrel 10 has an orifice and a connection end opposite the orifice. The outer shell 36 defines an orifice opening 38 at the orifice of the barrel 10. As described in detail below, the connection end is configured to connect the barrel 10 to an aerosol generating device. The heater assembly 12 and the heater holder 14 are positioned toward the connection end of the barrel 10.

[0267] The outer shell 36 is made of a moldable plastic material such as polypropylene. The outer shell 36 defines an interior space that accommodates the heater assembly 12 and the heater holder 14.

[0268] The outer width of the outer shell 36 is greater at the mouth end of the cartridge 10 than at the connection end, the mouth end and the connection end being joined by a shoulder 37. This enables the connection end of the cartridge 10 to be received in the cavity of the aerosol generating device, wherein the shoulder 37 locates the cartridge in the correct position in the device. This also enables the mouth end of the cartridge 10 to be retained outside the aerosol generating device, wherein the mouth end conforms to the external shape of the aerosol generating device.

[0269] The cartridge 10 further comprises a liquid reservoir 44. The liquid reservoir 44 is defined within the cartridge 10 for holding the liquid aerosol-forming substrate 42.

[0270] The liquid reservoir 44 extends from the mouth end of the outer shell 36 to the connection end of the outer shell 36 , and includes an annular space defined by the outer shell 36 .

[0271] The annular space has an internal passage 48 extending between the mouth end opening 38 and the open end of the internal passage 26 of the heater holder 14 .

[0272] The liquid reservoir 44 also includes two channels 45 defined between the inner surface of the outer shell 36 and the outer surface of the heater holder 14. The two channels 45 extend from the annular space defined by the outer shell 36 at the mouth end of the barrel 10 to the connection end of the barrel 10 so that the wicking element extends through the opening 28 in the side wall of the heater holder 14 into the two channels 45. The two channels 45 extend from the annular space defined by the outer shell 36 at the mouth end of the barrel 10 on opposite sides of the internal passage 26 of the heater holder 14.

[0273] The heater holder 14 includes a base 30 that partially closes one end of the internal passage 26. The base 30 includes a plurality of air inlets 32 that enable air to be drawn into the internal passage 26 through the partially closed end.

[0274] The internal passage 26 of the heater holder 14 and the internal passage 48 of the liquid reservoir 44 form an air passage through the cartridge 10. The air passage extends from the air inlet 32 ​​in the base 30 of the heater holder 14, through the internal passage 26 of the heater holder 14, and through the internal passage 48 of the liquid reservoir 44 to the mouth end opening 38. The air passage enables air to be drawn from the connection end through the cartridge 10 to the mouth end.

[0275] The heater holder 14 further comprises a first pair of meniscus forming elements 101 and two pairs of peripheral meniscus forming elements 102. In this particular embodiment, all the meniscus forming elements are elongated blades extending parallel to the longitudinal direction of the internal passage 26 of the heater holder 14. The meniscus forming elements 101, 102 are positioned adjacent to the susceptor elements 16, 18 such that, in use, a meniscus of the liquid aerosol-forming substrate is formed between the susceptor elements 16, 18 and the meniscus forming elements 101, 102. The meniscus forming elements 101, 102 extend across approximately half of the length of the susceptor elements 16, 18 in a direction parallel to the longitudinal axis of the heater holder 14. Figure 2 The positions of the meniscus forming elements 101, 102 can be seen more clearly in FIG.

[0276] Figure 2 Shows Figure 1A and 1B Schematic diagram of another alternative cross section of the barrel 10. Figure 1A and 1B The view shown in the viewing tube 10 makes Figure 1A The cross section shown in is indicated by the dashed line AB, and Figure 1B The cross section shown in is indicated by the dashed line CD.

[0277] The cartridge 10 includes a heater holder 14. The heater holder 14 includes a tubular body formed of a moldable plastic material such as polypropylene. The tubular body of the heater holder 14 includes a side wall 27 defining an internal passage 26 having an open end. A pair of openings 28 extend through the side wall 27 at opposite sides of the tubular heater holder 14. The openings 28 are centrally arranged along the length of the heater holder 14.

[0278] The opening 28 in the side wall of the heater holder 14 is sized to receive the heater assembly 12 in a friction fit so that the heater assembly is secured in the heater holder 14. The friction fit between the heater assembly 12 and the heater holder 14 causes the mounting area 22 to directly contact the heater holder 14 at the opening 28. The heater assembly 12 and the heater holder 14 are secured together so that movement of the heater holder 14 also moves the heater assembly 12.

[0279] It should be appreciated that the heater assembly 12 and the heater holder 14 may be secured together by other means. For example, in some embodiments, the heater assembly 12 is secured to the heater holder 14 by an adhesive at the mounting area 22 of the heater assembly 12 so that the mounting area 22 indirectly contacts the heater holder 14.

[0280] The two channels 45 are located on opposite sides of the internal passage 26 and, in use, the two channels 45 supply the liquid aerosol-forming substrate to the heater assembly 12. The wicking element 20 extends from the internal passage 26 via the opening 28 into two of the channels 45. The channels 45 are Figure 2 It is shown empty in the figure, but it will be understood that it is filled with a liquid aerosol-forming substrate prior to use.

[0281] exist Figure 2 The tube 10 is observed from the mouth end to the connection end. Figure 2 A plurality of air inlets 32 in the base 30 can be seen.

[0282] The cross-section of the heater assembly 12 may be Figure 2 1, wherein the wicking element 20 is disposed between the first susceptor element 16 and the second susceptor element 18. However, it is understood that the first susceptor element 16 and the second susceptor element 18 may instead be a single susceptor element wrapped around the wicking element 20, the single susceptor element including a first portion on a first side of the heater assembly 12 and a second portion on a second side of the heater assembly 12.

[0283] exist Figure 2 1. The position of the first pair of meniscus forming elements 101 and the two pairs of peripheral meniscus forming elements 102 can also be clearly seen in FIG. The first pair of meniscus forming elements 101 and the two pairs of peripheral meniscus forming elements 102 are all formed of a moldable plastic material such as polypropylene. The first pair of meniscus forming elements 101 are integrally molded with the side wall 27 defining the internal passage 26 and extend from the side wall 27 to the first surface and the second surface of the heater assembly 12. The first pair of meniscus forming elements 101 are positioned so that the first meniscus forming elements are directly opposite to the second meniscus forming elements on the directly opposite side of the heater assembly 12.

[0284] The first pair of meniscus-forming elements 101 are also centrally located relative to the susceptor elements 16, 18. Therefore, the first pair of meniscus-forming elements 101 are located furthest from the liquid reservoir 44 so that the liquid aerosol-forming substrate 42 must travel from the portion of the susceptor elements 16, 18 furthest from the liquid reservoir 44 to the portion of the susceptor elements 16, 18 adjacent to the first pair of meniscus-forming elements 101. If the susceptor elements 16, 18 are heated without the liquid aerosol-forming substrate 42 within the wicking element 20, the portion of the susceptor elements 16, 18 adjacent to the first pair of meniscus-forming elements 101 will be the hottest region of the susceptor elements 16, 18.

[0285] Two pairs of peripheral meniscus forming elements 102 are also integrally molded with the side wall 27 defining the internal passage 26 and extend from the side wall 27 to the first surface and the second surface of the heater assembly 12. The two pairs of peripheral meniscus forming elements 102 are also positioned on opposite sides of the heater assembly 12 such that within each pair of peripheral meniscus forming elements 102, a first peripheral meniscus forming element is directly opposite a second peripheral meniscus forming element on a directly opposite side of the heater assembly 12.

[0286] The meniscus forming elements 101, 102 each include a tip where the meniscus forming elements 101, 102 are adjacent to the first susceptor element or the second susceptor element 16. In this embodiment, the tip is pointed, but those skilled in the art will appreciate that the tip may be a different shape, for example the tip may be rounded.

[0287] A pair of meniscus forming elements 101 are shown forming a first pair of menisci 31 on opposite sides of the heating assembly 12. Two pairs of peripheral meniscus forming elements 102 can be seen forming one of two second pairs of menisci 33 on opposite sides of the heating assembly 12, respectively.

[0288] Figure 3A A schematic diagram of a cross-section of an aerosol generating system 100 according to a second embodiment of the present disclosure is shown, wherein the cartridge 10 is separated from the aerosol generating device 60 .

[0289] Tube 10 and Figure 1A , 1B The same as the barrel presented in 2 and its corresponding description.

[0290] The aerosol generating device 60 comprises a generally cylindrical device housing 62 having a connection end and a distal end opposite the connection end. A cavity 64 for receiving the connection end of the cartridge is located at the connection end of the device 60, and an air inlet 65 is provided through the device housing 62 at the base of the cavity 64 to allow ambient air to be drawn into the cavity 64.

[0291] The device 60 also includes an induction heating device disposed within the device housing 62. The induction heating device includes an inductor coil 90, a control circuit 70, and a power source 72. The power source 72 includes a rechargeable lithium-ion battery that can be recharged via an electrical connector (not shown) at a distal end of the device. The control circuit 70 is connected to the power supply 72 and to the inductor coil 90 so that the control circuit 70 controls the power supply to the inductor coil 90. The control circuit 70 is configured to supply an alternating current to the inductor coil 90.

[0292] When the cartridge 10 is received in the cavity 64, a single inductor coil 90 is positioned around the susceptor assembly 12. The inductor coil 90 has a size and shape that matches the size and shape of the heating area of ​​the susceptor element. The inductor coil 90 is made of copper wire having a circular cross-section and is arranged on a coil former element (not shown). The inductor coil 90 is a helical coil and has a circular cross-section when viewed parallel to the longitudinal axis of the aerosol generating device.

[0293] The inductor coil 90 is configured such that when an alternating current is supplied to the inductor coil, the inductor coil generates an alternating magnetic field in the region of the susceptor assembly 12 when the cartridge 10 is received in the cavity 64 .

[0294] The inductive heating device further comprises a flux concentrator element 91. The flux concentrator element 91 has a larger radius than the inductor coil 90 and therefore partially surrounds the inductor coil 90. The flux concentrator element 91 is configured to attenuate the alternating magnetic field outside the aerosol generating system. This may reduce interference between the alternating magnetic field and other nearby electronic devices and reduce the risk of the alternating magnetic field inductively heating nearby objects outside the aerosol generating system.

[0295] Figure 3B Shows Figure 3A Schematic diagram of a cross-section of an aerosol generating system 100 , but with the cartridge 10 coupled to an aerosol generating device 60 .

[0296] In operation, as indicated by the arrows in FIG. 7 a , when a user draws on the mouth end opening 38 of the cartridge 10, ambient air is drawn into the base of the chamber 64 through the air inlet 65 and into the cartridge 10 through the air inlet 32 ​​in the base 30 of the cartridge 10. Ambient air flows from the base 30 through the cartridge 10 to the mouth end opening 38, through the air passageway, and across the heater assembly 12.

[0297] When the system is activated, the control circuit 70 controls the supply of power from the power supply 72 to the inductor coils 90 , 91 .

[0298] The control circuit 72 includes an airflow sensor 63. The airflow sensor 63 is in fluid communication with the passage of ambient air drawn through the system by the user. When the airflow sensor 63 detects that the user is drawing on the cartridge 10, the control circuit 72 supplies power to the inductor coil 66.

[0299] When the system is activated, an alternating current is generated in the inductor coils 90, 91, which generates an alternating magnetic field in the cavity 64 that penetrates the susceptor assembly 12, causing the susceptor element to heat. The liquid aerosol-forming substrate in the passage 45 is drawn into the heater assembly 12 through the wicking element 20 to the susceptor element. The liquid aerosol-forming substrate 42 at the susceptor element is heated, and volatile compounds from the heated aerosol-forming substrate are released into the air passage of the cartridge 10, which cools to form an aerosol. The aerosol is entrained in the air drawn through the air passage of the cartridge 10 and is drawn out of the cartridge 10 at the mouth end opening 38 for inhalation by the user.

[0300] When the system is not activated, the meniscus forming elements 101, 102 cause a meniscus of liquid aerosol-forming substrate to form between each of the meniscus forming elements and one of the susceptor elements 16, 18. When the system is then activated, the meniscus of liquid aerosol-forming substrate acts as an additional reservoir for liquid aerosol-forming substrate, thereby allowing more liquid aerosol-forming substrate to be consumed with each puff.

[0301] Figure 4 A schematic diagram of a cross section of an aerosol generating device 300 according to a third embodiment of the present disclosure is shown. The aerosol generating device 300 according to the third embodiment of the present disclosure includes most of the components of the aerosol generating system 100 according to the second embodiment, and operates in a similar manner. Therefore, unless otherwise stated, the description of any element of the aerosol generating device 300 according to the third embodiment is the same as the description of the corresponding element of the cartridge according to the first embodiment or the aerosol generating device according to the second embodiment.

[0302] One difference is that the aerosol generating device 300 according to the third embodiment of the present disclosure does not include a separate cartridge, and most of the features of the cartridge 10 according to the first or second embodiment are instead incorporated into the aerosol generating device 300 according to the third embodiment. In addition, the aerosol generating device 300 according to the third embodiment of the present disclosure is resistively heated rather than inductively heated. However, the aerosol generating device 300 according to the third embodiment of the present disclosure may also be configured to be inductively heated instead.

[0303] As previously described, the aerosol generating device 300 according to the third embodiment comprises a generally cylindrical device outer housing 362 having a mouth end and a distal end opposite the mouth end. An air inlet 365 is provided into the device 300 through the device outer housing 362.

[0304] The device 300 also includes a resistive heating device disposed within the device housing 362. The resistive heating device includes a heating assembly 312, a control circuit 370, and a power supply 372. The power supply 372 includes a rechargeable nickel-cadmium battery that is recharged via an electrical connector (not shown) at the distal end of the device. The control circuit 370 is connected to the power supply 372 and the heating assembly 312 so that the control circuit 370 controls the supply of power to the heating assembly 312. The control circuit 370 is configured to supply current to the heating assembly 312, in particular to the two heating elements 316, 318. The heating assembly 312 is held in a heater holder 314.

[0305] The heater assembly 312 and the heater holder 314 are Figures 1A to 3B The heater assembly 12 and the heater holder 314 presented in FIG. 3 are the same, except that the heater assembly 312 is resistively heated, not inductively heated. Therefore, both heating elements 316, 318 are resistive heating elements. The heating elements 316, 318 are electrically connected to the power supply 372 and the control circuit 370 through an electrical connector (not shown). As previously described, the heater assembly 312 is planar and thin, having a thickness dimension substantially smaller than the length dimension and the width dimension. The heater assembly 312 is shaped in the form of a rectangle and includes three layers: a first resistive heating element 316, a second resistive heating element 318, and a wicking element 320 arranged between the first resistive heating element 316 and the second resistive heating element 318. Each of the first resistive heating element 316, the second resistive heating element 318, and the wicking element 320 is generally formed in the shape of a rectangle, and each resistive heating element has the same length and width dimensions, and the width of the resistive heating elements 316, 318 is less than the width of the wicking element 320. Thus, wicking element 320 includes externally exposed portions of the wicking element, each of which protrudes into one of the two channels 345. First and second resistive heating elements 316, 318 are substantially identical and include a sintered mesh of steel wire.

[0306] As previously described, the heater holder 314 also includes a base 330 that partially closes one end of the internal passage 326. The base 330 includes a plurality of air inlets that allow air to be drawn into the internal passage 326 through the partially closed end. As previously described, the heater holder 314 includes a tubular body formed of a moldable plastic material such as polypropylene. The tubular body of the heater holder 314 includes a side wall that defines the internal passage 326 having an open end. However, the skilled person will appreciate that since the device 300 does not include a removable cartridge, the heater holder can instead be formed integrally with the device 300, and in particular integrally with the device outer housing 362.

[0307] In addition, the arrangement and operation of the first pair of meniscus forming elements 301 and the two pairs of peripheral meniscus forming elements 302 are the same as the arrangement and operation of the first and second embodiments of the present disclosure. As previously described, all meniscus forming elements 301, 302 are elongated blades that extend parallel to the longitudinal direction of the internal passage 326 of the heater holder 314. The meniscus forming elements 301, 302 are positioned adjacent to the resistive heating elements 316, 318 so that in use, the meniscus of the liquid aerosol-forming substrate is formed between the resistive heating elements 316, 318 and the meniscus forming elements 301, 302. The meniscus forming elements 301, 302 extend across approximately half of the length of the resistive heating elements 316, 318 in a direction parallel to the longitudinal axis of the heater holder 314. Reference should be made again to Figure 2 and the associated description to fully describe the arrangement of the meniscus-forming elements 301 , 302 .

[0308] Similar to the first and second embodiments of the present disclosure, the aerosol generating device 300 also includes a liquid reservoir 344. The liquid reservoir 344 is defined by a device housing 362 for holding a liquid aerosol-forming substrate 342. The liquid reservoir 344 extends from the mouth end of the housing 362 to the connection end of the device housing 362, and includes an annular space defined by the device housing 362. The annular space has an internal passage 348 extending between the mouth end opening 338 and the open end of the internal passage 326 of the heater holder 314. The liquid reservoir 344 also includes two channels 345, which are defined between the outer surface of the heater holder 314 and the inner surface of the device. The two channels 345 extend from the annular space defined by the device housing 362 at the mouth end of the device 300 to the connection end of the device 300, so that the wicking element 320 extends through the opening in the side wall of the heater holder 314 into the two channels 345. Two channels 345 extend from an annular space defined by the device outer casing 362 at the oral end of the device 300 on opposite sides of the internal passage 326 of the heater holder 314.

[0309] Similar to the first and second embodiments of the present disclosure, an air passageway is formed through the device 300 through the internal passageway 326 of the heater holder 314 and the internal passageway 348 of the liquid reservoir 344. The air passageway extends from the air inlet in the base 330 of the heater holder 314, through the internal passageway 326 of the heater holder 314, and through the internal passageway 348 of the liquid reservoir 344 to the mouth end opening 338. The air passageway enables air to be drawn from the air inlet 365 to the mouth end opening 338 through the device 300.

[0310] Similar to the first and second embodiments of the present disclosure, the control circuit 372 includes an airflow sensor 363. The airflow sensor 363 is in fluid communication with the path of ambient air drawn by the user through the device 300. When the airflow sensor 363 detects that the user is drawing air on the device 300, the control circuit 372 supplies power to the heating elements 316, 318.

[0311] When the device is activated, an electric current is established in the resistive heating elements 316, 318, which causes the resistive heating elements 316, 318 to resistively heat. The liquid aerosol-forming substrate 342 in the passage 345 is drawn into the heater assembly 312 through the wicking element 320 to the resistive heating elements 316, 318. The liquid aerosol-forming substrate 342 at the heating elements is heated, and volatile compounds from the heated aerosol-forming substrate are released into the air passages 326, 348 of the device 300, which cool to form an aerosol. The aerosol is entrained in the air drawn through the air passages 326, 348 of the device 300 and is drawn out of the device 300 at the mouth end opening 338 for inhalation by the user.

[0312] Similar to the first and second embodiments of the present disclosure, when the system is not activated, the meniscus forming elements 301, 302 cause a meniscus of liquid aerosol-forming substrate to form between each of the meniscus forming elements and one of the resistive heating elements 316, 318. When the system is then activated, the meniscus of the liquid aerosol-forming substrate acts as an additional reservoir of the liquid aerosol-forming substrate, thereby allowing more liquid aerosol-forming substrate to be consumed with each puff.

[0313] For the purpose of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, 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. A cartridge for an aerosol generating system, the cartridge comprising: air inlet and air outlet; an air flow passage extending between the air inlet and the air outlet; a liquid reservoir comprising a liquid aerosol-forming substrate; a heater assembly comprising at least one heating element in fluid communication with the airflow passageway, the heater assembly being configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; as well as at least one meniscus-forming element, the at least one meniscus-forming element being proximate to the heater assembly; wherein each meniscus-forming element is positioned within the airflow passageway and contacts or is spaced apart from a surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus-forming element, and Wherein the at least one meniscus forming element comprises at least one blade or at least one needle.

2. The cartridge of claim 1, wherein each meniscus-forming element contacts or is spaced between 0 mm and 3 mm from a surface of the heater assembly.

3. The cartridge of claim 2, wherein each meniscus-forming element contacts or is spaced between 0 mm and 1 mm from a surface of the heater assembly.

4. A cartridge according to any preceding claim, wherein the airflow pathway is defined by an airflow pathway wall, and wherein the airflow pathway wall comprises an inner surface and the at least one meniscus-forming element extends from the inner surface.

5. A cartridge according to any preceding claim, wherein the at least one heating element comprises a susceptor element configured to be inductively heated.

6. A cartridge according to any preceding claim, wherein each of the at least one heating element comprises a high temperature zone which reaches a highest temperature during use, and wherein the at least one meniscus-forming element is proximal to the high temperature zone.

7. A barrel according to any preceding claim, wherein the heater assembly further comprises a wicking element in fluid communication with the at least one heating element and the liquid reservoir, and wherein the at least one heating element comprises a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element being opposite to the second side of the wicking element.

8. A cartridge according to claim 7, wherein the at least one meniscus-forming element comprises a first meniscus-forming element and a second meniscus-forming element, and wherein the first meniscus-forming element contacts the first heating element portion or is spaced apart from the first heating element portion such that, during use, a first meniscus of the liquid aerosol-forming substrate is formed between a surface of the first heating element portion and the first meniscus-forming element, and wherein the second meniscus-forming element contacts the second heating element portion or is spaced apart from the second heating element portion such that, during use, a second meniscus of the liquid aerosol-forming substrate is formed between a surface of the second heating element portion and the second meniscus-forming element.

9. The cartridge of claim 8, wherein the first and second meniscus-forming elements are adjacent to a central portion of the heater assembly.

10. A cartridge according to any preceding claim, wherein the air flow passage extends in a longitudinal direction such that the direction of air flow through the air flow passage is in the longitudinal direction. The cartridge of claim 10 , wherein the at least one blade comprises a tip.

12. The cartridge of claim 11, wherein the at least one vane extends perpendicular to a surface of the heater assembly, and wherein the at least one vane extends in a longitudinal direction of the airflow passageway.

13. A barrel according to any one of claims 4 to 12, wherein the at least one meniscus forming element includes at least one peripheral meniscus forming element, and wherein each of the at least one peripheral meniscus forming element is adjacent to one of the plurality of peripheral portions of the heater assembly, and each of the peripheral portions of the heater assembly is positioned adjacent to the airflow passage wall.

14. An aerosol generating system comprising a cartridge, the cartridge comprising: air inlet and air outlet; an air flow passage extending between the air inlet and the air outlet; a liquid reservoir comprising a liquid aerosol-forming substrate; a heater assembly comprising at least one heating element in fluid communication with the airflow passageway, the heater assembly being configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; as well as at least one meniscus-forming element, the at least one meniscus-forming element being proximate to the heater assembly; wherein each meniscus-forming element is positioned within the airflow passageway and contacts or is spaced apart from a surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus-forming element, and wherein the at least one meniscus forming element comprises at least one blade or at least one needle; as well as An aerosol generating device, the aerosol generating device comprising: a power source configured to supply power to the heating element; and a control circuit configured to control the supply of power from the power source to the at least one heating element; Wherein the cartridge is reversibly coupled to the aerosol generating device.

15. An aerosol generating device, comprising: air inlet and air outlet; an air flow passage extending between the air inlet and the air outlet; a liquid reservoir comprising a liquid aerosol-forming substrate; a heater assembly comprising at least one heating element in fluid communication with the airflow passageway, the heater assembly being configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; as well as at least one meniscus-forming element, the at least one meniscus-forming element being proximate to the heater assembly; wherein each meniscus-forming element is positioned within the airflow passageway and contacts or is spaced apart from a surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus-forming element, and wherein the at least one meniscus forming element comprises at least one blade or at least one needle; a power source configured to supply power to the heating element; as well as A control circuit is configured to control the supply of power from the power source to the at least one heating element.

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