Heater assembly with improved robustness for aerosol-generating devices

Abstract

A heater assembly (400) for an aerosol-generating device. The heater assembly (400) includes a heating element (430). The heating element (430) includes a plurality of heating portions (431) and at least one attachment portion (432). The heating element (430) includes a support structure (460) including a support structure aperture (461) and an upper support structure surface (462) parallel to the first plane. The heater assembly (400) includes a frame (420). The frame (420) at least partially surrounds the support structure (460). The heater assembly (400) includes a first electrical contact (491) in electrical contact with the first end of the heating element (430). The heater assembly (400) includes a second electrical contact (492) in electrical contact with the second end of the heating element (430). The heating element (430) provides a continuous electrical path between the first electrical contact (491) and the second electrical contact (492). The heating element (430) is fixed to the frame (420). Each heating portion (431) is within or overlies the support structure aperture (461) and is separated from the frame by at least one attachment portion (432). Each attachment portion includes a first section (433) and a second section (434). Each first section (433) is substantially parallel to the first plane. Each second section (434) extends from the upper support structure surface (462) towards a second plane that is parallel but not coplanar with the upper support structure surface (462).

Description

Technical Field

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

[0002] Aerosol generating systems configured to generate inhalable aerosols from aerosol-forming substrates are known in the art. Some previous aerosol generating systems include an aerosol generating device that can be connected to a tube. A typical tube for use with an aerosol generating device includes an aerosol-forming substrate and a heater assembly, wherein the heater assembly includes a heating element. Typically, the aerosol-forming substrate is a liquid. In this case, the tube 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 deliver 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 may be resistively heated. An airflow is arranged to pass through the heating element to entrain the generated vapor. In the airflow, the vapor condenses and forms an aerosol. Then the user can inhale the aerosol. The aerosol generating device typically includes a power supply that is configured to supply power to the heating element when the device and the tube are connected together via an electrical connector.

[0003] In this type of aerosol generating system, the heating element is fixed to the heater assembly, the aerosol generating device, the tube or other components of the aerosol generating system, depending on the position of the heating element. This provides stability for the heating element and can minimize damage to the heating element during use. However, when the heating element is at a high temperature during use, heat can be transferred from the heating element to the heater assembly, the aerosol generating device, the tube or other components of the aerosol generating system. This heat transfer may damage these other components. In addition, this heat transfer may cause the aerosol generating device, the tube or other components of the aerosol generating system to become very hot to the touch during use, which will impair the overall experience of the user. Summary of the invention

[0004] It would therefore be desirable to provide a heater assembly, aerosol generating device, cartridge and aerosol generating system which, during use, minimise heat transfer between the heating element and other components of the heater assembly, aerosol generating device, cartridge or aerosol generating system.

[0005] When the heating element is coupled to the wicking material, reliable physical contact between the heating element and the wicking material facilitates reliable aerosol generation. Therefore, the heating element is typically coupled to the wicking material so that the wicking material exerts a force on the heating element. Therefore, it would be beneficial to provide a heater assembly including a robust heating element so that when the heating element is coupled to the wicking material, the wicking material does not damage the heating element.

[0006] According to a first embodiment of the present disclosure, a heater assembly for an aerosol generating device is provided. The heater assembly may include a heating element, a first electrical contact electrically contacting a first end of the heating element, and a second electrical contact electrically contacting a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include a plurality of heating portions. The heating element may also include at least one attachment portion. At least one attachment portion may be positioned between the heating portions along the continuous electrical path. The heating element may include a frame, the frame including an orifice in a first plane, wherein the heating element is fixed to the frame. Each heating portion may be within or overlying the orifice. Each heating portion may be separated from the frame by at least one attachment portion. The heater assembly may also include a support structure. The frame may at least partially surround the support structure. The support structure may include a support structure orifice. The support structure orifice may be located in the first plane. At least a portion of the heating element may be within the support structure orifice. In particular, a plurality of heating portions may be within the support structure orifice. At least a portion of the heating element may overlie the support structure orifice. In particular, a plurality of heating portions may overlie the support structure orifice. The support structure may include an upper support structure surface parallel to a first plane. Each attachment portion may include a first section and a second section. Each first section may be substantially coplanar with the upper support structure surface. Each second section may extend from the upper support structure surface toward a second plane. The second plane may be parallel to but not coplanar with the upper support structure surface.

[0007] Advantageously, this arrangement may provide a more robust structure for the heating element. Also advantageously, such an arrangement means that when a wicking element in a cartridge is configured to contact a heating element, where the heating element is part of an aerosol generating device coupled to the cartridge, the wicking element need not protrude from the cartridge. Also advantageously, such features allow an aerosol to be easily delivered from the heating element, where the aerosol is generated, to a user.

[0008] The support structure orifice may be substantially circular. The support structure orifice may be substantially square or rectangular. The support structure orifice may be substantially oval. The support structure may include a heat-resistant polymer. For example, the support structure may include polyetheretherketone (PEEK). Alternatively, the support structure may include ceramic. For example, the support structure may include aluminum oxide. In another example, the support structure may include zirconium oxide. The support structure may include the same material as the frame. Alternatively, the support structure may include a different material from the frame. The support structure orifice may have a cross-sectional area between 1 square millimeter and 1000 square millimeters in the first plane. The support structure orifice may have a cross-sectional area between 2 square millimeters and 200 square millimeters in the first plane. Preferably, the support structure orifice has a cross-sectional area between 4 square millimeters and 50 square millimeters in the first plane.

[0009] At least a portion of the heating element may be coplanar with the upper support structure surface. The plurality of heating portions may be substantially coplanar with the upper support structure surface. Each second segment may extend in a direction perpendicular to the upper support structure surface. Each second segment may be positioned between the frame and the support structure. Each second segment may be fixed between the frame and the support structure. Advantageously, positioning or fixing each second segment between the frame and the support structure may produce a heating element that is securely fixed in place.

[0010] The first electrical contact and the second electrical contact may both comprise a first electrical contact section and a second electrical contact section. The two first electrical contact sections may be substantially coplanar with the upper support structure surface. The two second electrical contact sections may extend from the upper support structure surface toward the second plane. The two second electrical contact sections may extend in a direction perpendicular to the upper support structure surface. Advantageously, this arrangement may provide a more robust structure for the heating element.

[0011] The two second electrical contact sections may be positioned between the frame and the support structure. The two second electrical contact sections may be fixed between the frame and the support structure. Advantageously, positioning or fixing the two second electrical contact sections between the frame and the support structure may produce a heating element that is securely fixed in place.

[0012] The frame may include an upper surface coplanar with the upper support structure surface. The frame may include a lower frame surface. The support structure may include a lower support structure surface coplanar with the lower surface of the frame. Each of the first electrical contact and the second electrical contact may also include a third electrical contact section. The two third electrical contact sections may be substantially coplanar with the lower surface of the frame.

[0013] The plurality of heating portions may be coplanar with the upper surface of the frame.

[0014] The cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path. Advantageously, heat transfer from the heating element to the frame is thereby reduced. As a result, the frame may experience lower temperatures during use.

[0015] The plurality of heating portions and the at least one attachment portion may all be integrally formed. Advantageously, this may simplify manufacture and increase the robustness of the heating element.

[0016] Each attachment portion may be directly connected to exactly two heating portions. Each heating portion may be directly connected to exactly two attachment portions, or exactly one attachment portion and the first electrical contact or the second electrical contact. This arrangement may advantageously provide an electrical path that is easy to manufacture to ensure that the cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path.

[0017] Each heating portion may have a first width in the first direction, and each attachment portion may have a second width in the first direction, and the second width may be greater than the first width. Advantageously, this provides an arrangement that ensures that the cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path, and is directly manufactured by common manufacturing methods such as laser cutting, water jet cutting or chemical etching stamping.

[0018] Each heating portion may extend perpendicular to the first direction. The first direction may be located in a first plane. When the direction of the continuous electrical path is defined by each heating portion, the first direction may be perpendicular to the direction of the continuous electrical path. The ratio of the first width to the second width may be between 1 / 20 and 1 / 2. Preferably, the ratio of the first width to the second width is between 1 / 10 and 1 / 4. The first width may be between 0.1 mm and 2 mm. Preferably, the first width is between 0.2 mm and 1 mm. More preferably, the first width is between 0.2 mm and 0.5 mm.

[0019] The heating element may have a thickness in at least one direction perpendicular to the first direction. The thickness may be between 0.02 mm and 0.5 mm. Preferably, the thickness is between 0.05 mm and 0.3 mm. When the aerosol generating device is a handheld device, such dimensions may advantageously provide a heating element that is robust and can provide sufficient energy to heat the aerosol-forming substrate.

[0020] The heater assembly may include a gap between adjacent heating portions. The gap may have a gap width. The gap width may be in the first direction. The gap width may be between 0.1 mm and 1 mm. Preferably, the gap width is between 0.2 mm and 0.5 mm.

[0021] The plurality of heating sections may include 2 heating sections to 20 heating sections. Preferably, the plurality of heating sections includes 3 heating sections to 9 heating sections. More preferably, the plurality of heating sections includes 6 heating sections. Preferably, the plurality of heating sections includes an even number of heating sections. Advantageously, an even number of heating sections means that the first electrical contact and the second electrical contact can be positioned on the same side of the heater assembly.

[0022] The resistance per unit length of the plurality of heating portions in the direction of the conductive path may be greater than the resistance per unit length of at least one attachment portion in the direction of the conductive path. The resistance per unit length may be measured by measuring the resistance on each of the heating portion or the attachment portion and dividing the resistance by the length of each of the heating portion or the attachment portion in the direction of the conductive path. For example, if the attachment portion is curved, the direction of the conductive path may be a curve. The resistance of each heating portion may be higher than the resistance of each attachment portion.

[0023] The heater assembly can be configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the plurality of heating portions increases more than the temperature of the at least one attachment portion. The heater assembly can be configured such that when a non-zero current is applied through the heating element between the first electrical contact and the second electrical contact, the temperature of the plurality of heating portions increases more than the temperature of the at least one attachment portion. In these cases, the temperature of the plurality of heating portions and the temperature of the at least one attachment portion can be an average temperature over the length of each of the plurality of heating portions and the at least one attachment portion.

[0024] The heating element may be serpentine. The heating element may be serpentine in the first plane. The heating element may be serpentine when it protrudes onto the first plane. Advantageously, such an arrangement allows many heating portions to be positioned or packed in a reduced area. Additionally, the serpentine arrangement may be fluid permeable. The heater assembly may include spaces between the heating portions of the heating element. Thus, vapor generated by the heating element may pass through the serpentine heating element.

[0025] The heating element may comprise stainless steel. The heating element may comprise a ferrimagnetic material or a ferromagnetic material. Advantageously, when the frequency of the alternating current applied to the heating element is increased, the skin depth in the ferrimagnetic material or the ferromagnetic material decreases. The resistance of the heating element increases with frequency. Therefore, the use of a ferrimagnetic or ferromagnetic track may allow its resistance to be increased. This generates more heat locally without reducing the thickness and compromising the mechanical strength of the heating element.

[0026] The heating element may be coated with a corrosion resistant material. In particular, the heating element may be coated with a ceramic material. Advantageously, this may increase the life of the heating element and the heater assembly. This is particularly relevant because the heater assembly may be configured to reversibly couple and detach with the wicking element, and thus the heater assembly may be configured to be reusable.

[0027] The heating element may be substantially flat. Advantageously, this may simplify the manufacture of the heating element.

[0028] The total resistance of the heating element may be between 0.1 ohm and 5 ohm. Preferably, the total resistance of the heating element is between 0.2 ohm and 1.5 ohm.

[0029] The heating element and the first and second electrical contacts may be integrally formed. The heating element and the first and second electrical contacts may be formed from the same material. Advantageously, these features may simplify the manufacture of the heating element.

[0030] The orifice may be substantially square or rectangular. Alternatively, the orifice may be substantially circular. Advantageously, such a shape of the orifice may ensure that the wicking element is easily aligned with the orifice when the aerosol generating device is coupled to the cartridge. In addition, such a shape may be easy to manufacture for the orifice or corresponding wicking element.

[0031] The frame may be electrically insulating. In particular, the frame may have a thermal conductivity of 1 W / mK or less. This may advantageously ensure that the electrical path through the heating element is well defined as a single electrical path and minimize current through the frame, and therefore minimize resistive heating of the frame.

[0032] The frame may include a heat resistant polymer. For example, the frame may include polyetheretherketone (PEEK). Alternatively, the frame may include a ceramic. For example, the frame may include alumina. In another example, the frame may include zirconium oxide.

[0033] The frame may be overmolded over a section of the heating element. For example, the frame may be overmolded over an attachment section of at least one attachment portion. Additionally or alternatively, the frame may be overmolded over at least one attachment section of the first electrical contact and at least one section of the second electrical contact. Advantageously, the overmolding may provide a robust connection between the frame and the heating element.

[0034] The frame may include an upper element and a lower element. The upper element and the lower element may include a press-fit element so that the upper element and the lower element may be coupled together by a press-fit. Alternatively, the upper element and the lower element may include a snap-fit ​​element so that the upper element and the lower element may be coupled together by a snap-fit. Alternatively, the upper element and the lower element may include a fastening element so that the upper element and the lower element may be coupled together by fastening. Advantageously, a frame including an upper element and a lower element may provide a simplified manufacturing and modular system, wherein the heating element may be replaced, for example. When the upper element and the lower element are coupled together, at least one attachment section in at least one attachment portion may be located between the upper element and the lower element. Additionally or alternatively, when the upper element and the lower element are coupled together, at least one attachment section of the first electrical contact and at least one section of the second electrical contact may be located between the upper element and the lower element. Advantageously, such an arrangement ensures that the heating portion does not contact the frame.

[0035] The orifice may have a cross-sectional area in the first plane of between 1 square millimeter and 1000 square millimeters. Preferably, the orifice has a cross-sectional area in the first plane of between 2 square millimeters and 200 square millimeters. More preferably, the orifice has a cross-sectional area in the first plane of between 4 square millimeters and 50 square millimeters.

[0036] The heating element may further include at least one thermally insulating portion. Each attachment portion may be separated from the frame by a thermally insulating portion. Advantageously, the thermally insulating portion may further reduce the amount of heat transferred from the plurality of heating portions to the frame via the at least one attachment portion.

[0037] Each heating portion may be connected to the frame via at least one thermally insulating portion.

[0038] The plurality of heating portions, at least one attachment portion and at least one thermally isolating portion may all be integrally formed. Advantageously, this simplifies manufacturing, as the heating element may be produced by common manufacturing methods such as laser cutting, water jet cutting or chemical etching stamping.

[0039] Each thermal isolation portion may not be directly attached to any heating portion. An attachment portion may exist between each thermal isolation portion and any heating portion. Each thermal isolation portion may be located outside the continuous electrical path. For example, each thermal isolation portion may be located outside the continuous electrical path so that the temperature increase experienced by the thermal isolation portion due to direct resistive heating is lower than both the temperature increase of each attachment portion and the temperature increase of each heating portion.

[0040] Each heat insulating portion may have a third width in the first direction. The third width may be less than the second width. The ratio of the third width to the second width may be between 1 / 10 and 2 / 3. Preferably, the ratio of the third width to the second width is between 1 / 5 and 1 / 3. The third width may be substantially equal to the first width. Advantageously, this provides a heat insulating portion that reduces the amount of heat transferred from the heating portion to the frame while simplifying manufacture.

[0041] The thermal resistance on each attachment portion between adjacent heating portions and adjacent thermally insulating portions may be lower than the thermal resistance on each thermally insulating portion between adjacent attachment portions and the frame. Thermal resistance may define the temperature difference that an object or material resists against heat flow. The thermal resistance (R) on the attachment portion between adjacent heating portions and adjacent thermally insulating portions may be defined as:

[0042]

[0043] Where x is the length of each attachment portion measured between adjacent heating portions and adjacent thermal isolation portions in the direction of the thermal path, A is the cross-sectional area of ​​each attachment portion between adjacent heating portions and adjacent thermal isolation portions in the direction of the thermal path, and k is the thermal conductivity of each attachment portion, which is a material constant.

[0044] The same equation can be used to define the thermal resistance on each thermal isolation portion between an adjacent attachment portion and a frame, where x is the length of each thermal isolation portion measured between the adjacent attachment portion and the frame in the direction of the thermal path, A is the cross-sectional area of ​​each thermal isolation portion between the adjacent attachment portion and the frame in the direction of the thermal path, and k is the thermal conductivity of each thermal isolation portion, which is a material constant.

[0045] At least one heating portion may include a radius of curvature orthogonal to the first plane. At least one heating portion may include a finite radius of curvature orthogonal to the first plane. Each heating portion may include a radius of curvature orthogonal to the first plane. At least one heating portion may extend in a convex manner relative to the direction along which the wicking element may be coupled to the heater assembly. At least one heating portion may include at least two sections extending in at least two different directions that are not parallel to the first plane. At least one heating portion may extend out of the first plane in an arched shape. At least one heating portion may extend out of the first plane in a dome shape. At least one heating portion may bend out of the first plane. At least one heating portion may extend out of the first plane in an arcuate manner. At least one heating portion may include a radius of curvature orthogonal to the first plane, so that when at least one heating portion is reversibly deformed by a force so that at least one heating portion is parallel to the first plane, the reaction force applied by at least one heating portion at the center of the at least one heating portion is greater than the reaction force applied at the periphery of the at least one heating portion. Advantageously, when the aerosol generating device is coupled to the cartridge such that the heater assembly is coupled to the wicking element, the heating element may therefore exert a greater force at the centre of the connecting surface of the wicking element than at the periphery of the connecting surface of the wicking element.

[0046] Each heating portion may include the same radius of curvature orthogonal to the first plane. Alternatively, each heating portion may include a radius of curvature orthogonal to the first plane selected from a plurality of radii of curvature. For example, each heating portion may include a different radius of curvature orthogonal to the first plane.

[0047] The heater assembly can be configured so that when the wicking element is coupled to the heater assembly, the heating element applies force unevenly on the connecting surface of the wicking element. For example, the heating element can apply greater force at the center of the connecting surface of the wicking element than at the periphery of the connecting surface of the wicking element.

[0048] The heating element may comprise a resilient material. Advantageously, when the aerosol generating device is coupled to the cartridge such that the heater assembly is coupled to the wicking element, the heating element may therefore undergo resilient deformation rather than rupture.

[0049] The frame may comprise an upper surface parallel to the first plane. At least a first portion of the heating element may be recessed a first distance from the upper surface of the frame. The first distance may be between 0.2 mm and 5 mm. Advantageously, in particular if the heating element is uncovered and on an outer surface of the aerosol generating device, such an arrangement may protect at least the first portion of the heating element from damage. The attachment section of the at least one attachment portion may be recessed a first distance from the upper surface of the frame.

[0050] At least a second portion of the heating element may coincide with a plane formed by the upper surface of the frame. Advantageously, this arrangement means that the protrusion required for the wicking element is minimized, wherein the wicking element is configured to contact the heating element when a cartridge including the wicking element is coupled to an aerosol generating device including a heater assembly. At least a second portion of the heating element may coincide with a plane formed by the upper surface of the frame. At least a second portion of the heating element may extend beyond the plane formed by the upper surface of the frame. A radius of curvature orthogonal to the first plane may be applied to the second portion of the heating element.

[0051] Alternatively, the entire heating element may be recessed a first distance from the upper surface of the frame. Advantageously, and as described above, this arrangement may protect the entire heating element from damage, particularly if the heating element is uncovered and on an outer surface of the aerosol generating device.

[0052] The frame may include a lower surface parallel to the first plane. At least a first portion of the heating element may be recessed from the lower surface of the frame by a second distance. The second distance may be between 0.2 mm and 5 mm.

[0053] The attachment section of the at least one attachment portion may be recessed a second distance from the lower surface of the frame.Advantageously, such an arrangement may protect at least the at least one attachment portion from damage, particularly during handling of the heater assembly and components of the aerosol generating device.

[0054] According to a second embodiment of the present disclosure, an aerosol generating device is provided. The aerosol generating device may include a heater assembly. The aerosol generating device may include a heater assembly according to the first embodiment of the present disclosure. The heater assembly may include a heating element. The heater assembly may include a first electrical contact electrically contacting a first end of the heating element. The heater assembly may include a second electrical contact electrically contacting a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include a plurality of heating portions. The heating element may include at least one attachment portion positioned between the heating portions along the continuous electrical path. The heater assembly may include a frame. The frame may include an orifice in a first plane. The heating element may be fixed to the frame. Each heating portion may be within the orifice. Each heating portion may overlie the orifice. Each heating portion may be separated from the frame by at least one attachment portion. The heater assembly may also include a support structure. The frame may at least partially surround the support structure. The support structure may include a support structure orifice. The support structure orifice may be located in the first plane. At least a portion of the heating element may be within the support structure orifice. In particular, a plurality of heating portions may be within the support structure orifice. At least a portion of the heating element may overlie the support structure aperture. In particular, a plurality of heating portions may overlie the support structure aperture. The support structure may include an upper support structure surface parallel to a first plane. Each attachment portion may include a first section and a second section. Each first section may be substantially parallel to the first plane. Each first section may be substantially coplanar with the upper support structure surface. Each second section may extend from the upper support structure surface toward the second plane. The second plane may be parallel to but not coplanar with the upper support structure surface. Advantageously, this arrangement may provide a more robust structure for the heating element. The aerosol generating device may further include an airflow passage defined between an air inlet and an air outlet. The airflow passage may be in fluid communication with the heating element. In particular, the airflow passage may be in fluid communication with a first side of the heating element. The airflow passage may pass through the heater assembly. The heater assembly may include a heater assembly airflow passage between the heater assembly air inlet and the heater assembly air outlet. The aerosol generating device may further include a power supply. The power supply may be in electrical contact with the first electrical contact and the second electrical contact. The power supply may be configured to supply power to the heating element. The aerosol generating device may further include a control circuit. The control circuit may be configured to control the supply of power from the power supply to the heating element.

[0055] The battery may be a lithium-based battery, such as lithium cobalt, lithium iron phosphate, lithium titanate, or a lithium polymer battery. The battery may be a nickel metal hydride battery or a nickel cadmium battery. The power source may be another form of charge storage device, such as a capacitor.

[0056] The control circuit may be connected to a power source. The control circuit may be connected to a heating element. The control circuit may control the supply of power from the power source to the heating element. The control circuit may control the temperature of the heating element. The control circuit may include a controller. The control circuit system may include a microcontroller. The microcontroller may be a programmable microcontroller.

[0057] The aerosol generating device may be a handheld aerosol generating device. The aerosol generating device may have a size comparable to a conventional cigar or cigarette. The aerosol generating device may have an overall length of between about 25 mm and about 150 mm. The outer diameter of the aerosol generating device may be between about 5 mm and about 30 mm.

[0058] The control circuit may further include a puff detector in fluid communication with the airflow path. The device may be configured so that the heating element is actuated by puffing. Advantageously, this can reduce energy consumption of the battery and ensure that aerosol is only generated when required by the user.

[0059] The air inlet may be defined in a side wall of the device. The air outlet may be defined in an end wall of the device. The air outlet may be defined in a proximal wall of the device. Advantageously, an air outlet defined in a proximal wall of the device means that a cartridge including a mouthpiece may be easily coupled to the proximal wall and therefore to the air outlet. The side wall of the device may extend perpendicularly to the end wall of the device.

[0060] According to a third embodiment of the present disclosure, an aerosol generating system is provided. The aerosol generating system may include a barrel. The barrel may include an aerosol-forming substrate. The barrel may include a reservoir for accommodating the aerosol-forming substrate. The aerosol-forming substrate may be in fluid communication with a wicking material. The wicking material may form a portion of an outer surface of the barrel.

[0061] An aerosol generating system may include an aerosol generating device. The aerosol generating system may include an aerosol generating device according to a second embodiment of the present disclosure. The aerosol generating device may include a heater assembly. The aerosol generating device may include a heater assembly according to a first embodiment of the present disclosure. The heater assembly may include a heating element. The heater assembly may also include a first electrical contact electrically contacting a first end of the heating element. The heater assembly may also include a second electrical contact electrically contacting a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact.

[0062] The heating element may comprise a plurality of heating portions. The heating element may further comprise at least one attachment portion. The at least one attachment portion may be positioned between the heating portions along the continuous electrical path.

[0063] The heater assembly may include a frame. The frame may include an aperture. The frame may include an aperture in a first plane.

[0064] The heating element may be fixed to the frame. Each heating portion may be within the aperture. Each heating portion may overlie the aperture. Each heating portion may be detachable from the frame by at least one attachment portion. The heater assembly may further include a support structure. The frame may at least partially surround the support structure. The support structure may include a support structure aperture. The support structure aperture may be located in a first plane. At least a portion of the heating element may be within the support structure aperture. In particular, a plurality of heating portions may be within the support structure aperture. At least a portion of the heating element may overlie the support structure aperture. In particular, a plurality of heating portions may overlie the support structure aperture. The support structure may include an upper support structure surface parallel to the first plane. Each attachment portion may include a first section and a second section. Each first section may be substantially parallel to the first plane. Each first section may be substantially coplanar with the upper support structure surface. Each second section may extend from the upper support structure surface toward the second plane. The second plane may be parallel to but not coplanar with the upper support structure surface. Advantageously, this arrangement may provide a more robust structure for the heating element. A cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path may be smaller than a cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path.

[0065] The aerosol generating system may include a system air flow path defined between a system air inlet and a system air outlet. In particular, as in the second embodiment, the aerosol generating device may also include an air flow path defined between the air inlet and the air outlet. The system air flow path may include an air flow path of the device. The system air inlet may include an air inlet of the device. The system air outlet may include an air outlet of the device. The air flow path of the device may be in fluid communication with the heating element. In particular, the air flow path of the device may be in fluid communication with a first side of the heating element. The system air flow path may pass through the heater assembly. In particular, the air flow path of the device may pass through the heater assembly. The heater assembly may include a heater assembly air flow path between the heater assembly air inlet and the heater assembly air outlet. The air inlet of the device may include the heater assembly air inlet. The system air flow path may include a heater assembly air flow path. In particular, the air flow path of the device may include a heater assembly air flow path.

[0066] The aerosol generating device may further comprise a power source. The power source may be in electrical contact with the first electrical contact and the second electrical contact. The power source may be configured to supply power to the heating element. The aerosol generating device may further comprise a control circuit. The control circuit may be configured to control the supply of power from the power source to the heating element. Advantageously, the power supplied to the heating element may thus be varied based on usage behavior.

[0067] The cartridge may be reversibly coupled to the aerosol generating device. The cartridge may be reversibly coupled to the aerosol generating device so that when the cartridge is coupled to the device, the wicking material is in direct contact with the heating element. Advantageously, the cartridge may be reversibly coupled to the aerosol generating device meaning that the cartridge may be disposed of once empty or damaged and replaced by a new cartridge. This may save costs and have environmental benefits because there are fewer components to be disposed of. The wicking element may have a cross-sectional area equal to the cross-sectional area of ​​the orifice. The wicking element may have a cross-sectional shape substantially the same as the cross-sectional shape of the orifice.

[0068] The airflow passage of the aerosol generating device may be in fluid communication with the first side of the heating element. When the cartridge is coupled to the device, the wicking material may be in direct contact with the second side of the heating element. The first side of the heating element may be opposite to the second side of the heating element.

[0069] The cartridge may further include a cartridge air flow passage defined between the cartridge air inlet and the cartridge air outlet.

[0070] The cartridge may also include a removable seal covering a portion of the cartridge. In particular, the cartridge may also include a removable seal covering the wicking element. The removable seal may be configured to be removed by a user.

[0071] When the cartridge is coupled to the device, the cartridge air inlet may be in fluid communication with the device's air outlet.

[0072] The cartridge air outlet may include a mouthpiece.

[0073] The aerosol generating system may be a handheld aerosol generating system configured to allow a user to draw on a mouthpiece to inhale an aerosol through a cartridge air outlet. The aerosol generating system may have a size comparable to a conventional cigar or cigarette. The aerosol generating system may have an overall length between about 25 mm and about 150 mm. The aerosol generating system may have an outer diameter between about 5 mm and about 30 mm.

[0074] Aerosol formation substrate can be liquid. In particular, aerosol formation substrate can be liquid at standard temperature and pressure. Advantageously, this ensures that when the system is used at standard temperature and pressure, liquid aerosol formation substrate can be easily transported to the wicking element from the reservoir, and then transported to the heating element. Aerosol formation substrate can be liquid at room temperature. Aerosol formation substrate can be another condensation form, such as a solid at room temperature, or can be another condensation form, such as a gel at room temperature. Volatile compounds can be released by heating aerosol formation substrate. Aerosol formation substrate can include both liquid component and solid component. Liquid aerosol formation substrate can include nicotine. Nicotine-containing liquid aerosol formation substrate can be a nicotine salt substrate. Liquid aerosol formation substrate can include plant-based materials. Liquid aerosol formation substrate can include tobacco. Liquid aerosol formation substrate can include a tobacco-containing material comprising volatile tobacco flavor compounds, and volatile tobacco flavor compounds are released from aerosol formation substrate when heated. Liquid aerosol formation substrate can include homogenized tobacco material. The liquid aerosol-forming substrate may comprise a tobacco-free material.The liquid aerosol-forming substrate may comprise a homogenised plant-based material.

[0075] The liquid aerosol-forming substrate may include one or more aerosol formers. An aerosol former is any suitable known compound or mixture of compounds that promotes the formation of a dense and stable aerosol in use and is substantially resistant to thermal degradation at the operating temperature of the system. Examples of suitable aerosol formers include glycerol and propylene glycol. Suitable aerosol formers are well known in the art and include, but are not limited to: polyols such as triethylene glycol, 1,3-butylene glycol and glycerol; esters of polyols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The liquid aerosol-forming substrate may contain water, solvents, ethanol, plant extracts and natural or artificial flavors. The liquid aerosol-forming substrate may contain nicotine and at least one aerosol former. The aerosol former may be glycerol or propylene glycol. The aerosol former may contain both glycerol and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of between about 0.5% and about 10%, for example about 2%.

[0076] According to a fourth embodiment of the present disclosure, a cartridge for an aerosol generating system is provided. The cartridge may include an aerosol-forming substrate. The cartridge may include an aerosol-forming substrate as described with respect to the third embodiment. The aerosol-forming substrate may be in fluid communication with a wicking material.

[0077] The cartridge may include a heater assembly. The cartridge may include a heater assembly according to a first embodiment of the present disclosure. The cartridge may be configured to be coupled to an aerosol generating device. The heater assembly may be coupled and detached from the cartridge body. The heater assembly may include a heating element. The heater assembly may include a first electrical contact in electrical contact with a first end of the heating element. The heater assembly may include a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include a plurality of heating portions. The heating element may include at least one attachment portion positioned between the heating portions along the continuous electrical path. The heater assembly may include a frame. The frame may include an orifice in a first plane. The heating element may be fixed to the frame. Each heating portion may be within the orifice. Each heating portion may overlie the orifice. Each heating portion may be detached from the frame by at least one attachment portion. The heater assembly may also include a support structure. The frame may at least partially surround the support structure. The support structure may include a support structure orifice. The support structure orifice may be located in the first plane. At least a portion of the heating element may be within the support structure orifice. In particular, a plurality of heating portions may be within the support structure orifice. At least a portion of the heating element may overlie the support structure aperture. In particular, a plurality of heating portions may overlie the support structure aperture. The support structure may include an upper support structure surface parallel to a first plane. Each attachment portion may include a first section and a second section. Each first section may be substantially parallel to the first plane. Each first section may be substantially coplanar with the upper support structure surface. Each second section may extend from the upper support structure surface toward a second plane. The second plane may be parallel to, but not coplanar with, the upper support structure surface. Advantageously, this arrangement may provide a more robust structure for the heating element.

[0078] The cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path. The heater assembly may form part of the outer surface of the barrel. The wicking material may be in contact with the heating element.

[0079] The barrel may also include a barrel airflow path. The barrel airflow path may be defined between the barrel air inlet and the barrel air outlet. The barrel airflow path may be in fluid communication with the heating element. In particular, the barrel airflow path may be in fluid communication with the first side of the heating element. The barrel airflow path may pass through the heater assembly. The heater assembly may include a heater assembly airflow path between the heater assembly air inlet and the heater assembly air outlet. The barrel air inlet may include a heater assembly air inlet.

[0080] The cartridge may be configured to be coupled to an aerosol generating device.The cartridge may be configured to be coupled to an aerosol generating device such that the cartridge air inlet is aligned with a device air outlet of the aerosol generating device.

[0081] The cartridge air outlet may include a mouthpiece.

[0082] The aerosol-forming substrate may be a liquid. In particular, the aerosol-forming substrate may be a liquid at standard temperature and pressure. Advantageously, this ensures that when the system is used at standard temperature and pressure, the liquid aerosol-forming substrate can be easily transported from the reservoir to the wicking element, and then to the heating element.

[0083] As used herein, the term "heating element" refers to an element of a heater assembly that is configured to be heated. For example, the term "heating element" may refer to an element configured to heat at least a portion of the element to at least 50, 100, 150, 200, 250, or 300 degrees Celsius.

[0084] As used herein, the term "coupled or coupleable" is used to indicate that the cartridge and the device can be coupled to and separated from each other without significant damage to the device or the cartridge.

[0085] As used herein, the term "serpentine" is used to define the shape of a path that, when viewed perpendicular to a plane of the path, includes at least one curve or bend in the path of approximately 180 degrees such that a first area of ​​the shape is located next to a second area of ​​the shape. Thus, the shape may resemble a single Latin letter 'S' or multiple Latin letter 'S's connected end to end.

[0086] As used herein, the terms "air inlet" and "air outlet" are used to describe one or more apertures through which air can be drawn into and out of, respectively, a heater assembly, an aerosol generating system, a cartridge or a component or portion of a component of an aerosol generating device.

[0087] As used herein with reference to the present invention, the term "aerosol" is used to describe a dispersion of solid particles or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. Aerosols may be visible or invisible. Aerosols may include vapors of substances that are normally liquid or solid at room temperature, as well as solid particles or liquid droplets, or a combination of solid particles and liquid droplets.

[0088] As used herein, an "aerosol generating system" refers to a system that generates an aerosol from one or more aerosol-forming substrates.

[0089] As used herein, the term "aerosol-forming substrate" refers to a substrate that is capable of releasing volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate.

[0090] 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.

[0091] Example Ex1: A heater assembly for an aerosol generating device, the heater assembly comprising:

[0092] a heating element, wherein the heating element comprises a plurality of heating portions and at least one attachment portion,

[0093] a support structure comprising a support structure aperture and an upper support structure surface parallel to the first plane,

[0094] a frame at least partially surrounding the support structure,

[0095] a first electrical contact in electrical contact with the first end of the heating element, and

[0096] a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact,

[0097] wherein the heating element is fixed to the frame, and wherein each heating portion is within or overlying the support structure aperture and is separated from the frame by at least one attachment portion,

[0098] Each attachment portion includes a first section and a second section, and each first section is substantially parallel to the first plane, and each second section extends from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface.

[0099] Example Ex2: The heater assembly according to example Ex1, wherein each second segment extends in a direction perpendicular to the surface of the upper support structure.

[0100] Example Ex3: The heater assembly of example Ex1 or Ex2, wherein at least a portion of the heating element is coplanar with the upper support structure surface.

[0101] Example Ex4: The heater assembly according to example Ex3, wherein the plurality of heating portions are coplanar with the upper support structure surface.

[0102] Example Ex5: The heater assembly according to any preceding example, wherein each second segment is fixed between the frame and the support structure.

[0103] Example Ex6: A heater assembly according to any of the preceding examples, wherein the first electrical contact and the second electrical contact both include a first electrical contact segment and a second electrical contact segment, and wherein the two first electrical contact segments are substantially parallel to the first plane, and the two second electrical contact segments extend from the upper support structure surface toward the second plane.

[0104] Example Ex7: The heater assembly according to Example Ex6, wherein the two second electrical contact sections extend in a direction perpendicular to the surface of the upper support structure.

[0105] Example Ex8: The heater assembly according to example Ex6 or Ex7, wherein two second electrical contact sections are fixed between the frame and the support structure.

[0106] Example Ex9: The heater assembly according to any preceding example, wherein the frame includes an upper surface, the upper surface of the frame being coplanar with the upper support structure surface.

[0107] Example Ex10: The heater assembly according to any preceding example, wherein the frame includes an upper surface, the upper surface of the frame being recessed from the upper support structure surface.

[0108] Example Ex11: A heater assembly according to any of the preceding examples, wherein the frame includes a lower surface, and wherein the support structure includes a lower surface that is coplanar with the lower surface of the frame, wherein both the first electrical contact and the second electrical contact further include a third electrical contact segment, and wherein the two third electrical contact segments are substantially coplanar with the lower surface of the frame.

[0109] Example Ex12: The heater assembly according to any preceding example, wherein the resistance of the plurality of heating portions is higher than the resistance of the at least one attachment portion.

[0110] Example Ex13: The heater assembly according to any of the preceding examples, wherein a cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path is smaller than a cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path.

[0111] Example Ex14: A heater assembly according to any of the preceding examples, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating portions increases more than the temperature of the at least one attachment portion.

[0112] Example Ex 15: The heater assembly according to any preceding example, wherein the plurality of heating portions and the at least one attachment portion are all integrally formed.

[0113] Example Ex16: The heater assembly according to any preceding example, wherein each attachment portion is directly connected to exactly two heating portions.

[0114] Example Ex17: The heater assembly according to any preceding example, wherein each heating portion is directly connected to exactly two attachment portions, or exactly one attachment portion and the first electrical contact or the second electrical contact.

[0115] Example Ex18: A heater assembly according to any of the preceding examples, wherein each heating portion has a first width in a first direction, wherein when the direction of the continuous electrical path is defined by each heating portion, the first direction may be perpendicular to the direction of the continuous electrical path, and each attachment portion has a second width in the first direction, and wherein the second width is greater than the first width.

[0116] Example Ex19: The heater assembly according to example Ex18, wherein a ratio of the first width to the second width is between 1 / 20 and 1 / 2.

[0117] Example Ex20: The heater assembly according to example Ex19, wherein a ratio of the first width to the second width is between 1 / 10 and 1 / 4.

[0118] Example Ex21: The heater assembly according to example Ex18, Ex19 or Ex20, wherein the first width is between 0.1 mm and 2 mm.

[0119] Example Ex22: The heater assembly according to example Ex21, wherein the first width is between 0.2 mm and 1 mm.

[0120] Example Ex23: The heater assembly according to example Ex22, wherein the first width is between 0.2 mm and 0.5 mm.

[0121] Example Ex24: The heater assembly according to any one of Examples Ex18 to Ex23, wherein the heating element has a thickness in at least one direction perpendicular to the first direction.

[0122] Example Ex25: A heater assembly according to Example Ex24, wherein the thickness is between 0.02 mm and 0.5 mm.

[0123] Example Ex26: A heater assembly according to Example Ex25, wherein the thickness is between 0.05 mm and 0.3 mm.

[0124] Example Ex27: The heater assembly according to any of the preceding examples, wherein the resistance per unit length of the plurality of heating portions in the direction of the conductive path is greater than the resistance per unit length of the at least one attachment portion in the direction of the conductive path.

[0125] Example Ex28: A heater assembly according to any preceding example, wherein the heating element is serpentine-shaped.

[0126] Example Ex 29: A heater assembly according to any preceding example, wherein the heating element comprises stainless steel.

[0127] Example Ex30: The heater assembly according to any preceding example, wherein the heating element comprises a ferrimagnetic material or a ferromagnetic material.

[0128] Example Ex31: The heater assembly according to any of the preceding examples, wherein the heating element is coated with a corrosion-resistant material.

[0129] Example Ex 32: The heater assembly according to any preceding example, wherein the heating element is coated with a ceramic material.

[0130] Example Ex33: The heater assembly according to any of the preceding examples, wherein the total resistance of the heating element is between 0.1 ohms and 5 ohms.

[0131] Example Ex34: A heater assembly according to Example Ex33, wherein the total resistance of the heating element is between 0.2 ohms and 1.5 ohms.

[0132] Example Ex35: The heater assembly according to any preceding example, wherein the heating element and the first and second electrical contacts are integrally formed.

[0133] Example Ex36: The heater assembly according to any preceding example, wherein the heating element and the first and second electrical contacts are formed of the same material.

[0134] Example Ex37: A heater assembly according to any preceding example, wherein the support structure aperture is substantially square or rectangular.

[0135] Example Ex38: A heater assembly according to any preceding example, wherein the support structure aperture is substantially circular.

[0136] Example Ex 39: A heater assembly according to any preceding example, wherein the frame is electrically insulating.

[0137] Example Ex40: A heater assembly according to Example Ex39, wherein the frame has a thermal conductivity of 1 W / mK or less.

[0138] Example Ex41: A heater assembly according to example Ex39 or Ex40, wherein the frame comprises a heat resistant polymer.

[0139] Example Ex42: A heater assembly according to any one of Examples Ex39 to Ex41, wherein the frame comprises polyetheretherketone (PEEK).

[0140] Example Ex43: A heater assembly according to Example Ex39 or Ex42, wherein the frame comprises ceramic.

[0141] Example Ex44: A heater assembly according to example Ex43, wherein the frame comprises aluminum oxide.

[0142] Example Ex45: A heater assembly according to example Ex43, wherein the frame comprises zirconium oxide.

[0143] Example Ex46: The heater assembly according to any preceding example, wherein the support structure aperture has a cross-sectional area in the first plane between 1 square millimeter and 1000 square millimeters.

[0144] Example Ex47: The heater assembly of Example Ex46, wherein the support structure aperture has a cross-sectional area in the first plane between 2 square millimeters and 200 square millimeters.

[0145] Example Ex48: The heater assembly of Example Ex47, wherein the support structure aperture has a cross-sectional area in the first plane between 4 square millimeters and 50 square millimeters.

[0146] Example Ex49: The heater assembly according to any preceding example, wherein each heating portion includes a radius of curvature orthogonal to the first plane.

[0147] Example Ex50: The heater assembly according to any preceding example, wherein the heating element comprises an elastic material.

[0148] Example Ex51: An aerosol generating device, comprising a heater assembly, the heater assembly comprising:

[0149] a heating element, wherein the heating element comprises a plurality of heating portions and at least one attachment portion,

[0150] a support structure comprising a support structure aperture and an upper support structure surface parallel to the first plane,

[0151] a frame at least partially surrounding the support structure,

[0152] a first electrical contact in electrical contact with the first end of the heating element, and

[0153] a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact,

[0154] wherein the heating element is fixed to the frame, and wherein each heating portion is within or overlying the support structure aperture and is separated from the frame by at least one attachment portion,

[0155] wherein each attachment portion includes a first segment and a second segment, and wherein each first segment is substantially parallel to the first plane, and each second segment extends from the upper support structure surface toward a second plane, the second plane being parallel but not coplanar with the upper support structure surface;

[0156] an air flow passage defined between the air inlet and the air outlet, the air flow passage being in fluid communication with the heating element,

[0157] a power source in electrical contact with the first electrical contact and the second electrical contact and configured to supply power to the heating element, and

[0158] A control circuit is configured to control the supply of power from the power source to the heating element.

[0159] Example Ex52: An aerosol generating device according to example Ex51, wherein the aerosol generating device is a handheld aerosol generating device.

[0160] Example Ex53: An aerosol generating device according to example Ex51 or Ex52, wherein the control circuit further comprises a puff detector in fluid communication with the airflow pathway, and the device is configured such that the heating element is actuated by puff.

[0161] Example Ex54: An aerosol generating device according to any one of Examples Ex51 to Ex53, wherein the air inlet is defined in a side wall of the device.

[0162] Example Ex55: An aerosol generating device according to example Ex54, wherein the air outlet is defined in an end wall of the device.

[0163] Example Ex56: An aerosol generating device according to example Ex55, wherein the side walls of the device extend perpendicularly to the end walls of the device.

[0164] Example Ex57: An aerosol generating device according to any one of Examples Ex51 to Ex56, wherein each second segment extends in a direction perpendicular to the surface of the upper support structure.

[0165] Example Ex58: An aerosol generating device according to any one of Examples Ex51 to Ex57, wherein at least a portion of the heating element is coplanar with the upper support structure surface.

[0166] Example Ex59: An aerosol generating device according to example Ex58, wherein the plurality of heating portions are coplanar with the upper support structure surface.

[0167] Example Ex60: An aerosol generating device according to examples Ex51 to Ex59, wherein each second section is fixed between the frame and the support structure.

[0168] Example Ex61: An aerosol generating device according to any one of Examples Ex51 to Ex60, wherein the first electrical contact and the second electrical contact both include a first electrical contact segment and a second electrical contact segment, and wherein the two first electrical contact segments are substantially parallel to the first plane, and the two second electrical contact segments extend from the upper support structure surface toward the second plane.

[0169] Example Ex62: An aerosol generating device according to example Ex61, wherein the two second electrical contact sections extend in a direction perpendicular to the surface of the upper support structure.

[0170] Example Ex63: An aerosol generating device according to example Ex61 or Ex62, wherein two second electrical contact sections are fixed between the frame and the supporting structure.

[0171] Example Ex64: An aerosol generating device according to any one of Examples Ex51 to Ex63, wherein the frame comprises an upper surface, the upper surface of the frame being coplanar with the upper support structure surface.

[0172] Example Ex65: An aerosol generating device according to examples Ex51 to Ex64, wherein the frame comprises an upper surface, the upper surface of the frame being recessed from the upper support structure surface.

[0173] Example Ex66: An aerosol generating device according to any one of Examples Ex63 to Ex65, wherein the frame includes a lower surface, and wherein the support structure includes a lower surface that is coplanar with the lower surface of the frame, wherein both the first electrical contact and the second electrical contact further include a third electrical contact segment, and wherein the two third electrical contact segments are substantially coplanar with the lower surface of the frame.

[0174] Example Ex67: An aerosol generating device according to Examples Ex51 to Ex66, wherein the resistance of the plurality of heating portions is higher than the resistance of the at least one attachment portion.

[0175] Example Ex68: An aerosol generating device according to examples Ex51 to Ex67, wherein a cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path is smaller than a cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path.

[0176] Example Ex69: An aerosol generating device according to any one of Examples Ex51 to Ex68, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating portions increases more than the temperature of the at least one attached portion.

[0177] Example Ex70: An aerosol generating device according to any one of Examples Ex51 to Ex69, wherein the plurality of heating portions and the at least one attachment portion are all integrally formed.

[0178] Example Ex71: An aerosol generating device according to any one of Examples Ex51 to Ex70, wherein each attachment portion is directly connected to exactly two heating portions.

[0179] Example Ex72: An aerosol generating device according to any one of Examples Ex51 to Ex71, wherein each heating portion is directly connected to exactly two attachment portions, or exactly one attachment portion and the first electrical contact or the second electrical contact.

[0180] Example Ex73: An aerosol generating device according to any one of Examples Ex51 to Ex72, wherein each heating portion has a first width in a first direction, and each attachment portion has a second width in the first direction, and wherein the second width is greater than the first width.

[0181] Example Ex74: An aerosol generating device according to example Ex73, wherein a ratio of the first width to the second width is between 1 / 20 and 1 / 2.

[0182] Example Ex75: An aerosol generating device according to example Ex74, wherein a ratio of the first width to the second width is between 1 / 10 and 1 / 4.

[0183] Example Ex76: An aerosol generating device according to example Ex73, Ex74 or Ex75, wherein the first width is between 0.1 mm and 2 mm.

[0184] Example Ex77: An aerosol generating device according to example Ex76, wherein the first width is between 0.2 mm and 1 mm.

[0185] Example Ex78: An aerosol generating device according to example Ex77, wherein the first width is between 0.2 mm and 0.5 mm.

[0186] Example Ex79: An aerosol generating device according to any one of Examples Ex76 to Ex78, wherein the heating element has a thickness in at least one direction perpendicular to the first direction.

[0187] Example Ex80: An aerosol generating device according to example Ex79, wherein the thickness is between 0.02 mm and 0.5 mm.

[0188] Example Ex81: An aerosol generating device according to example Ex80, wherein the thickness is between 0.05 mm and 0.3 mm.

[0189] Example Ex82: An aerosol generating device according to any one of Examples Ex51 to Ex81, wherein the resistance per unit length of the plurality of heating portions in the direction of the conductive path is greater than the resistance per unit length of the at least one attachment portion in the direction of the conductive path.

[0190] Example Ex83: An aerosol generating device according to any one of Examples Ex51 to Ex82, wherein the heating element is serpentine-shaped.

[0191] Example Ex84: An aerosol generating device according to any one of Examples Ex51 to Ex83, wherein the heating element comprises stainless steel.

[0192] Example Ex85: An aerosol generating device according to any one of Examples Ex51 to Ex84, wherein the heating element comprises a ferrimagnetic material or a ferromagnetic material.

[0193] Example Ex86: An aerosol generating device according to any one of Examples Ex51 to Ex85, wherein the heating element is coated with a corrosion-resistant material.

[0194] Example Ex87: An aerosol generating device according to any one of Examples Ex51 to Ex86, wherein the heating element is coated with a ceramic material.

[0195] Example Ex88: An aerosol generating device according to any one of Examples Ex51 to Ex87, wherein the total resistance of the heating element is between 0.1 ohms and 5 ohms.

[0196] Example Ex89: An aerosol generating device according to example Ex88, wherein the total resistance of the heating element is between 0.2 ohms and 1.5 ohms.

[0197] Example Ex90: An aerosol generating device according to any one of Examples Ex51 to Ex89, wherein the heating element and the first and second electrical contacts are integrally formed.

[0198] Example Ex91: An aerosol generating device according to any one of Examples Ex51 to Ex90, wherein the heating element and the first and second electrical contacts are formed of the same material.

[0199] Example Ex92: An aerosol generating device according to any one of Examples Ex51 to Ex91, wherein the support structure aperture is substantially square or rectangular.

[0200] Example Ex93: An aerosol generating device according to any one of Examples Ex51 to Ex91, wherein the support structure aperture is substantially circular.

[0201] Example Ex94: An aerosol generating device according to any one of Examples Ex51 to Ex93, wherein the frame is electrically insulating.

[0202] Example Ex95: An aerosol generating device according to example Ex94, wherein the frame has a thermal conductivity of 1 W / mK or less.

[0203] Example Ex96: An aerosol generating device according to example Ex94 or Ex95, wherein the frame comprises a heat-resistant polymer.

[0204] Example Ex97: An aerosol generating device according to any one of Examples Ex94 to Ex96, wherein the frame comprises polyetheretherketone (PEEK).

[0205] Example Ex98: An aerosol generating device according to example Ex94 or Ex95, wherein the frame comprises ceramic.

[0206] Example Ex99: An aerosol generating device according to example Ex98, wherein the frame comprises aluminum oxide.

[0207] Example Ex100: An aerosol generating device according to example Ex98, wherein the frame comprises zirconium oxide.

[0208] Example Ex101: An aerosol generating device according to any one of Examples Ex51 to Ex100, wherein the support structure aperture has a cross-sectional area in the first plane between 1 square millimeter and 1000 square millimeters.

[0209] Example Ex102: An aerosol generating device according to example Ex101, wherein the support structure aperture has a cross-sectional area in the first plane between 2 square millimeters and 200 square millimeters.

[0210] Example Ex103: An aerosol generating device according to example Ex102, wherein the support structure aperture has a cross-sectional area in the first plane between 4 square millimeters and 50 square millimeters.

[0211] Example Ex104: An aerosol generating device according to any one of Examples Ex51 to Ex103, wherein each heating portion comprises a radius of curvature orthogonal to the first plane.

[0212] Example Ex105: An aerosol generating device according to any one of Examples Ex51 to Ex104, wherein the heating element comprises an elastic material.

[0213] Example Ex106: An aerosol generating system, comprising:

[0214] A cartridge, comprising:

[0215] an aerosol-forming substrate in fluid communication with the wicking material,

[0216] wherein the wicking material forms part of the outer surface of the barrel, and

[0217] An aerosol generating device, the aerosol generating device comprising:

[0218] A heater assembly, the heater assembly comprising:

[0219] a heating element, wherein the heating element comprises a plurality of heating portions and at least one attachment portion,

[0220] a support structure comprising a support structure aperture and an upper support structure surface parallel to the first plane,

[0221] a frame at least partially surrounding the support structure,

[0222] a first electrical contact in electrical contact with the first end of the heating element, and

[0223] a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact,

[0224] wherein the heating element is fixed to the frame, and wherein each heating portion is within or overlying the support structure aperture and is separated from the frame by at least one attachment portion,

[0225] wherein each attachment portion includes a first segment and a second segment, and wherein each first segment is substantially parallel to the first plane, and each second segment extends from the upper support structure surface toward a second plane, the second plane being parallel but not coplanar with the upper support structure surface;

[0226] an air flow passage defined between the air inlet and the air outlet, the air flow passage being in fluid communication with the heating element,

[0227] a power source in electrical contact with the first electrical contact and the second electrical contact and configured to supply power to the heating element, and

[0228] a control circuit configured to control the supply of power from the power source to the heating element,

[0229] wherein the cartridge is reversibly coupleable to the aerosol generating device such that when the cartridge is coupled to the device, the wicking material is in direct contact with the heating element.

[0230] Example Ex107: An aerosol generating system according to example Ex106, wherein the airflow passage is in fluid communication with a first side of the heating element, and when the cartridge is coupled to the device, the wicking material is in direct contact with a second side of the heating element.

[0231] Example Ex108: An aerosol generating system according to example Ex106 or Ex107, wherein the cartridge further comprises a cartridge air flow passage defined between the cartridge air inlet and the cartridge air outlet.

[0232] Example Ex109: An aerosol generating system according to example Ex108, wherein when the cartridge is coupled to the device, the cartridge air inlet is in fluid communication with an air outlet of the device.

[0233] Example Ex110: An aerosol generating system according to example Ex108 or Ex109, wherein the cartridge air outlet comprises a mouthpiece.

[0234] Example Ex111: An aerosol generating system according to any one of Examples Ex106 to Ex110, wherein the aerosol-forming substrate is liquid at standard temperature and pressure.

[0235] Example Ex112: An aerosol generating system according to any one of Examples Ex106 to Ex111, wherein each second segment extends in a direction perpendicular to the surface of the upper support structure.

[0236] Example Ex113: An aerosol generating system according to any one of Examples Ex106 to Ex112, wherein at least a portion of the heating element is coplanar with the upper support structure surface.

[0237] Example Ex114: An aerosol generating system according to example Ex113, wherein the plurality of heating portions are coplanar with the upper support structure surface.

[0238] Example Ex115: An aerosol generating system according to any one of Examples Ex106 to Ex114, wherein each second segment is fixed between the frame and the support structure.

[0239] Example Ex116: An aerosol generating system according to any one of Examples Ex106 to Ex115, wherein the first electrical contact and the second electrical contact both include a first electrical contact segment and a second electrical contact segment, and wherein the two first electrical contact segments are substantially parallel to the first plane, and the two second electrical contact segments extend from the upper support structure surface toward the second plane.

[0240] Example Ex117: An aerosol generating system according to example Ex116, wherein the two second electrical contact sections extend in a direction perpendicular to the surface of the upper support structure.

[0241] Example Ex118: An aerosol generating system according to example Ex116 or Ex117, wherein two second electrical contact sections are fixed between the frame and the supporting structure.

[0242] Example Ex119: An aerosol generating system according to any one of Examples Ex106 to Ex118, wherein the frame comprises an upper surface, the upper surface of the frame being coplanar with the upper support structure surface.

[0243] Example Ex120: An aerosol generating system according to any one of Examples Ex106 to Ex119, wherein the frame comprises an upper surface, the upper surface of the frame being recessed from the upper support structure surface.

[0244] Example Ex121: An aerosol generating system according to any one of Examples Ex118 to Ex120, wherein the frame includes a lower surface, and wherein the support structure includes a lower surface that is coplanar with the lower surface of the frame, wherein both the first electrical contact and the second electrical contact further include a third electrical contact segment, and wherein the two third electrical contact segments are substantially coplanar with the lower surface of the frame.

[0245] Example Ex122: An aerosol generating system according to any one of Examples Ex106 to Ex121, wherein the resistance of the plurality of heating portions is higher than the resistance of the at least one attachment portion.

[0246] Example Ex123: An aerosol generating system according to any one of Examples Ex106 to Ex122, wherein the cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path.

[0247] Example Ex124: An aerosol generating system according to any one of Examples Ex106 to Ex123, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating portions increases more than the temperature of the at least one attached portion.

[0248] Example Ex125: An aerosol generating system according to any one of Examples Ex106 to Ex124, wherein the plurality of heating portions and the at least one attachment portion are all integrally formed.

[0249] Example Ex126: An aerosol generating system according to any one of Examples Ex106 to Ex125, wherein each attachment portion is directly connected to exactly two heating portions.

[0250] Example Ex127: An aerosol generating system according to any one of Examples Ex106 to Ex126, wherein each heating portion is directly connected to exactly two attachment portions, or exactly one attachment portion and the first electrical contact or the second electrical contact.

[0251] Example Ex128: An aerosol generating system according to any one of Examples Ex106 to Ex127, wherein each heating portion has a first width in a first direction, and each attachment portion has a second width in the first direction, and wherein the second width is greater than the first width.

[0252] Example Ex129: An aerosol generating system according to example Ex128, wherein a ratio of the first width to the second width is between 1 / 20 and 1 / 2.

[0253] Example Ex130: An aerosol generating system according to example Ex129, wherein a ratio of the first width to the second width is between 1 / 10 and 1 / 4.

[0254] Example Ex131: An aerosol generating system according to example Ex128, Ex129 or Ex130, wherein the first width is between 0.1 mm and 2 mm.

[0255] Example Ex132: An aerosol generating system according to example Ex131, wherein the first width is between 0.2 mm and 1 mm.

[0256] Example Ex133: An aerosol generating system according to example Ex132, wherein the first width is between 0.2 mm and 0.5 mm.

[0257] Example Ex134: An aerosol generating system according to any one of Examples Ex128 to Ex133, wherein the heating element has a thickness in at least one direction perpendicular to the first direction.

[0258] Example Ex135: An aerosol generating system according to example Ex134, wherein the thickness is between 0.02 mm and 0.5 mm.

[0259] Example Ex136: An aerosol generating system according to example Ex135, wherein the thickness is between 0.05 mm and 0.3 mm.

[0260] Example Ex137: An aerosol generating system according to any one of Examples Ex106 to Ex136, wherein the resistance per unit length of the plurality of heating portions in the direction of the conductive path is greater than the resistance per unit length of the at least one attachment portion in the direction of the conductive path.

[0261] Example Ex138: An aerosol generating system according to any one of Examples Ex106 to Ex137, wherein the heating element is serpentine-shaped.

[0262] Example Ex139: An aerosol generating system according to any one of Examples Ex106 to Ex138, wherein the heating element comprises stainless steel.

[0263] Example Ex140: An aerosol generating system according to any one of Examples Ex106 to Ex139, wherein the heating element comprises a ferrimagnetic material or a ferromagnetic material.

[0264] Example Ex141: An aerosol generating system according to any one of Examples Ex106 to Ex140, wherein the heating element is coated with a corrosion-resistant material.

[0265] Example Ex142: An aerosol generating system according to any one of Examples Ex106 to Ex141, wherein the heating element is coated with a ceramic material.

[0266] Example Ex143: An aerosol generating system according to any one of Examples Ex106 to Ex142, wherein the total resistance of the heating element is between 0.1 ohms and 5 ohms.

[0267] Example Ex144: An aerosol generating system according to example Ex143, wherein the total resistance of the heating element is between 0.2 ohms and 1.5 ohms.

[0268] Example Ex145: An aerosol generating system according to any one of Examples Ex106 to Ex144, wherein the heating element and the first and second electrical contacts are integrally formed.

[0269] Example Ex146: An aerosol generating system according to any one of Examples Ex106 to Ex145, wherein the heating element and the first and second electrical contacts are formed of the same material.

[0270] Example Ex147: An aerosol generating system according to any one of Examples Ex106 to Ex146, wherein the support structure aperture is substantially square or rectangular.

[0271] Example Ex148: An aerosol generating system according to any one of Examples Ex106 to Ex146, wherein the support structure aperture is substantially circular.

[0272] Example Ex149: An aerosol generating system according to any one of Examples Ex106 to Ex148, wherein the frame is electrically insulating.

[0273] Example Ex150: An aerosol generating system according to example Ex149, wherein the frame has a thermal conductivity of 1 W / mK or less.

[0274] Example Ex151: An aerosol generating system according to example Ex149 or Ex150, wherein the frame comprises a heat-resistant polymer.

[0275] Example Ex152: An aerosol generating system according to any one of Examples Ex149 to Ex151, wherein the frame comprises polyetheretherketone (PEEK).

[0276] Example Ex153: An aerosol generating system according to example Ex149 or Ex150, wherein the frame comprises ceramic.

[0277] Example Ex154: An aerosol generating system according to example Ex153, wherein the frame comprises aluminum oxide.

[0278] Example Ex155: An aerosol generating system according to example Ex153, wherein the frame comprises zirconium oxide.

[0279] Example Ex156: An aerosol generating system according to any one of Examples Ex106 to Ex155, wherein the support structure aperture has a cross-sectional area in the first plane between 1 mm2 and 1000 mm2.

[0280] Example Ex157: An aerosol generating system according to example Ex156, wherein the support structure aperture has a cross-sectional area in the first plane between 2 square millimeters and 200 square millimeters.

[0281] Example Ex158: An aerosol generating system according to example Ex157, wherein the support structure aperture has a cross-sectional area in the first plane between 4 square millimeters and 50 square millimeters.

[0282] Example Ex159: An aerosol generating system according to any one of Examples Ex106 to Ex158, wherein each heating portion comprises a radius of curvature orthogonal to the first plane.

[0283] Example Ex160: An aerosol generating system according to any one of Examples Ex106 to Ex159, wherein the heating element comprises an elastic material.

[0284] Example Ex161: A cartridge for an aerosol generating system, the cartridge comprising:

[0285] an aerosol-forming substrate in fluid communication with the wicking material,

[0286] as well as

[0287] A heater assembly, the heater assembly comprising:

[0288] a heating element, wherein the wicking material is in contact with the heating element, and wherein the heating element comprises a plurality of heating portions and at least one attachment portion,

[0289] a support structure comprising a support structure aperture and an upper support structure surface parallel to the first plane,

[0290] a frame at least partially surrounding the support structure,

[0291] a first electrical contact in electrical contact with the first end of the heating element, and

[0292] a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact,

[0293] wherein the heating element is fixed to the frame, and wherein each heating portion is within or overlying the support structure aperture and is separated from the frame by at least one attachment portion,

[0294] Each attachment portion includes a first section and a second section, and each first section is substantially parallel to the first plane, and each second section extends from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface.

[0295] Example Ex162: The cartridge according to example Ex161, wherein the cartridge is configured to be reversibly coupled to and detached from the aerosol generating device.

[0296] Example Ex163: The cartridge according to Example Ex161 or Ex162, further comprising a cartridge air flow passage defined between the cartridge air inlet and the cartridge air outlet.

[0297] Example Ex164: A cartridge according to example Ex163, wherein the cartridge air outlet comprises a mouthpiece.

[0298] Example Ex165: A cartridge according to any one of Examples Ex161 to Ex164, wherein the aerosol-forming substrate is liquid at standard temperature and pressure.

[0299] Example Ex166: The barrel according to any one of Examples Ex161 to Ex165, wherein each second segment extends in a direction perpendicular to the surface of the upper support structure.

[0300] Example Ex167: The cartridge according to any one of Examples Ex161 to Ex166, wherein at least a portion of the heating element is coplanar with the upper support structure surface.

[0301] Example Ex168: A cartridge according to example Ex167, wherein the plurality of heating portions are coplanar with the upper support structure surface.

[0302] Example Ex169: The cartridge according to any one of Examples Ex161 to Ex168, wherein each second segment is fixed between the frame and the support structure.

[0303] Example Ex170: A tube according to any one of Examples Ex161 to Ex169, wherein the first electrical contact and the second electrical contact both include a first electrical contact segment and a second electrical contact segment, and wherein the two first electrical contact segments are substantially parallel to the first plane, and the two second electrical contact segments extend from the upper support structure surface toward the second plane.

[0304] Example Ex171: The cartridge according to example Ex170, wherein the two second electrical contact sections extend in a direction perpendicular to the surface of the upper support structure.

[0305] Example Ex172: The cartridge according to example Ex170 or Ex171, wherein two second electrical contact sections are fixed between the frame and the support structure.

[0306] Example Ex173: The cartridge according to any one of Examples Ex161 to Ex172, wherein the frame comprises an upper surface, the upper surface of the frame being coplanar with the upper support structure surface.

[0307] Example Ex174: The cartridge according to any one of Examples Ex161 to Ex173, wherein the frame comprises an upper surface, the upper surface of the frame being recessed from the upper support structure surface.

[0308] Example Ex175: A barrel according to any one of Examples Ex172 to Ex174, wherein the frame includes a lower surface, and wherein the support structure includes a lower surface that is coplanar with the lower surface of the frame, wherein both the first electrical contact and the second electrical contact further include a third electrical contact segment, and wherein the two third electrical contact segments are substantially coplanar with the lower surface of the frame.

[0309] Example Ex176: The cartridge according to any one of Examples Ex161 to Ex175, wherein the resistance of the plurality of heating portions is higher than the resistance of the at least one attachment portion.

[0310] Example Ex177: A cartridge according to any one of Examples Ex161 to Ex176, any one of Examples Ex379 to E, wherein the cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of ​​each attachment portion perpendicular to the direction of the continuous electrical path.

[0311] Example Ex178: A cartridge according to any one of Examples Ex161 to Ex177, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the plurality of heating portions increases more than the temperature of the at least one attachment portion.

[0312] Example Ex179: A cartridge according to any one of Examples Ex161 to Ex178, wherein the plurality of heating portions and the at least one attachment portion are all integrally formed.

[0313] Example Ex180: A cartridge according to any one of Examples Ex161 to Ex179, wherein each attachment portion is directly connected to exactly two heating portions.

[0314] Example Ex181: A cartridge according to any one of Examples Ex161 to Ex180, wherein each heating portion is directly connected to exactly two attachment portions, or exactly one attachment portion and the first electrical contact or the second electrical contact.

[0315] Example Ex182: A cartridge according to any one of Examples Ex161 to Ex181, wherein each heating portion has a first width in a first direction, and each attachment portion has a second width in the first direction, and wherein the second width is greater than the first width.

[0316] Example Ex183: The cartridge according to example Ex182, wherein a ratio of the first width to the second width is between 1 / 20 and 1 / 2.

[0317] Example Ex184: The cartridge according to example Ex183, wherein a ratio of the first width to the second width is between 1 / 10 and 1 / 4.

[0318] Example Ex185: A cartridge according to example Ex182, Ex183 or Ex184, wherein the first width is between 0.1 mm and 2 mm.

[0319] Example Ex186: A cartridge according to example Ex185, wherein the first width is between 0.2 mm and 1 mm.

[0320] Example Ex187: A cartridge according to example Ex186, wherein the first width is between 0.2 mm and 0.5 mm.

[0321] Example Ex188: The cartridge according to any one of Examples Ex161 to Ex187, wherein the heating element has a thickness in at least one direction perpendicular to the first direction.

[0322] Example Ex189: A barrel according to example Ex188, wherein the thickness is between 0.02 mm and 0.5 mm.

[0323] Example Ex190: A cartridge according to example Ex189, wherein the thickness is between 0.05 mm and 0.3 mm.

[0324] Example Ex191: A cartridge according to any one of Examples Ex161 to Ex190, wherein the resistance per unit length of the plurality of heating portions in the direction of the conductive path is greater than the resistance per unit length of the at least one attachment portion in the direction of the conductive path.

[0325] Example Ex192: A cartridge according to any one of Examples Ex161 to Ex191, wherein the heating element is serpentine.

[0326] Example Ex193: A cartridge according to any one of Examples Ex161 to Ex192, wherein the heating element comprises stainless steel.

[0327] Example Ex194: The cartridge according to any one of Examples Ex161 to Ex193, wherein the heating element comprises a ferrimagnetic material or a ferromagnetic material.

[0328] Example Ex195: The cartridge according to any one of Examples Ex161 to Ex194, wherein the heating element is coated with a corrosion-resistant material.

[0329] Example Ex196: The cartridge according to any one of Examples Ex161 to Ex195, wherein the heating element is coated with a ceramic material.

[0330] Example Ex197: The cartridge according to any one of Examples Ex161 to Ex196, wherein the total resistance of the heating element is between 0.1 ohms and 5 ohms.

[0331] Example Ex198: A cartridge according to example Ex197, wherein the total resistance of the heating element is between 0.2 ohms and 1.5 ohms.

[0332] Example Ex199: The cartridge according to any one of Examples Ex161 to Ex198, wherein the heating element and the first and second electrical contacts are integrally formed.

[0333] Example Ex200: The cartridge according to any one of Examples Ex161 to Ex199, wherein the heating element and the first and second electrical contacts are formed of the same material.

[0334] Example Ex201: The cartridge according to any one of Examples Ex161 to Ex200, wherein the support structure aperture is substantially square or rectangular.

[0335] Example Ex202: The cartridge according to any one of Examples Ex161 to Ex201, wherein the support structure aperture is substantially circular.

[0336] Example Ex203: The cartridge according to any one of Examples Ex161 to Ex202, wherein the frame is electrically insulating.

[0337] Example Ex204: The cartridge according to example Ex203, wherein the frame has a thermal conductivity of 1 W / mK or less.

[0338] Example Ex205: A cartridge according to example Ex203 or Ex204, wherein the frame comprises a heat-resistant polymer.

[0339] Example Ex206: The cartridge according to any one of Examples Ex203 to Ex205, wherein the frame comprises polyetheretherketone (PEEK).

[0340] Example Ex207: A cartridge according to example Ex203 or Ex204, wherein the frame comprises ceramic.

[0341] Example Ex208: A cartridge according to example Ex207, wherein the frame comprises aluminum oxide.

[0342] Example Ex209: A cartridge according to example Ex207, wherein the frame comprises zirconium oxide.

[0343] Example Ex210: The cartridge according to any one of Examples Ex161 to Ex209, wherein the support structure aperture has a cross-sectional area in the first plane between 1 square millimeter and 1000 square millimeters.

[0344] Example Ex211: The cartridge according to example Ex210, wherein the support structure aperture has a cross-sectional area in the first plane between 2 square millimeters and 200 square millimeters.

[0345] Example Ex212: The cartridge according to example Ex211, wherein the support structure aperture has a cross-sectional area in the first plane between 4 square millimeters and 50 square millimeters.

[0346] Features of one aspect or embodiment of the invention may be applied to other aspects or embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0347] Several examples will now be further described with reference to the accompanying drawings, in which:

[0348] Figure 1A shows a perspective view of a heater assembly;

[0349] Figure 1B Shows Figure 1A a plan view of a heater assembly;

[0350] Figure 1C Shows Figure 1A a side view of a heater assembly;

[0351] Figure 2A shows a perspective view of another heater assembly;

[0352] Figure 2B Shows Figure 2A a plan view of a heater assembly;

[0353] Figure 3A shows a perspective view of yet another heater assembly;

[0354] Figure 3B Shows Figure 3A a side view of a heater assembly;

[0355] Figure 4A shows a perspective view of yet another heater assembly;

[0356] Figure 4B Shows Figure 4A a perspective view of a heater assembly of FIG. 1 , wherein selected components of the heater assembly are shown as transparent;

[0357] Figure 5A schematic cross-sectional view of an aerosol generating device is shown, wherein the aerosol generating device comprises Figures 1A to 4B A heater assembly as shown in any one of the following;

[0358] Figure 6 A schematic cross-sectional view of an aerosol generating system is shown, wherein the aerosol generating system comprises Figure 5 An aerosol generating device as shown in , and a cartridge coupled to the aerosol generating device; and

[0359] Figure 7 A schematic diagram showing a cross section of a cartridge according to yet another embodiment, the cartridge comprising: Figures 1A to 4B A heater assembly as shown in any one of the. DETAILED DESCRIPTION

[0360] Figure 1A A perspective view of a heater assembly 100 is shown. The heater assembly 100 is for use in an aerosol generating system, such as an electrically operated smoking system, commonly referred to as an electronic cigarette system. The aerosol generating system may be a handheld, portable system and be comparable in size to a conventional cigar or cigarette.

[0361] The heater assembly 100 includes a frame 120. The frame 120 has a length and a width in a first plane and a height perpendicular to the first plane, the length and the width being greater than the height. Therefore, the frame 120 has an upper surface extending in the first plane. The frame 120 is approximately square in the first plane. The corners of the frame 120 in the first plane are rounded. The frame 120 includes an orifice 121, which is centrally located in the frame 120. The orifice 121 passes through the frame perpendicular to the first plane. The orifice 121 is approximately square parallel to the first plane. In this embodiment, the orifice 121 has the same shape as the frame 120, but this may not always be the case. The area of ​​the orifice is 100mm 2 For example, a substantially square frame may include a substantially circular aperture. Figure 1A In the embodiment shown in , the frame is formed from a heat resistant polymer, such as PEEK, but other suitable materials may alternatively be used.

[0362] The heater assembly 100 also includes a heating element 130. Figure 1A In the embodiment shown in , the heating element 130 is parallel to the first plane. The heating element 130 includes a plurality of heating portions 131 and at least one attachment portion 132. Figure 1A In the embodiment shown in FIG. 1 , the heating element 130 includes seven heating portions 131 and six attachment portions 132. Figure 1A In the embodiment shown in , the plurality of heating portions 131 and the at least one attachment portion 132 are integrally formed and comprise stainless steel.

[0363] The heater assembly 100 also includes a first electrical contact 191 and a second electrical contact 192. The first electrical contact 191 is attached to a first end of the heating element 130. The second electrical contact 192 is attached to a second end of the heating element 130. The heating element 130 forms a serpentine continuous electrical path between the first electrical contact 191 and the second electrical contact 192. This continuous electrical path has a total resistance of approximately 1 ohm. A portion of the heating element 130 overlies the aperture 121. In particular, each of the sections of the heating portion 131 and the attachment portion 132 overlies the aperture 121. A portion of the first electrical contact 191 and the second electrical contact 192 protrude from opposite sides of the frame 120 to allow electrical connection to external electronic devices.

[0364] The attachment portions 132 are each attached to the frame 120. In particular, in this embodiment, the frame 120 is overmolded on the attachment sections of the attachment portions 132. The first electrical contact 191 and the second electrical contact 192 are also attached to the frame 120. In particular, in this embodiment, the frame 120 is overmolded on the attachment sections of the first electrical contact 191 and the second electrical contact 192. However, in alternative embodiments, overmolding the frame on the attachment sections can be replaced by snap-fitting, press-fitting, or fastening the two frame elements together.

[0365] The heating element 130 and the first and second electrical contacts 191 , 192 are integrally formed and cut from a flat metal sheet, for example by laser cutting, water jet cutting or chemical etching.

[0366] In this first embodiment, the heating element 130 is uncoated, however, the heating element 130 may be coated by a thin layer of corrosion resistant material to increase the life of the heating element 130. An example of such a material is a ceramic material.

[0367] Figure 1B Shown according to Figure 1A 1 is a plan view of a heater assembly 100 of an embodiment of the present invention. The heating portion 131 is shown as having a first width 141 in the first direction, and the attachment portion is shown as also having a second width 142 in the first direction. The second width is greater than the first width. The first width is approximately 0.5 mm. The second width is approximately 1.5 mm. Therefore, the ratio of the first width to the second width is approximately 1 / 3. The serpentine shape of the heating element 130 is more clearly seen in this plan view. The heating portion 131 is shown as having a constant width equal to the first width in the first direction along its entire length. The attachment portion 131 is also shown as having a constant width equal to the second width in the first direction along its entire length.

[0368] Figure 1C Shown according to Figure 1A and 1B1. A side view of a heater assembly 100 of an embodiment of the present invention. The side view is in a first plane. It can be seen that the heating element 130 is generally planar in the first plane because the heating element 130 extends further in the first plane than perpendicular to the first plane. The heating element 130 is shown as having a uniform thickness perpendicular to the first plane. The thickness of the heating element is about 0.1 mm. Therefore, the heating portion 131 and the attachment portion 132 have approximately equal thickness perpendicular to the first plane. The heating element 130 is recessed from the upper surface 122 of the frame 120. The heating element 130 is recessed from the upper surface 122 of the frame 120 by approximately 2 mm. Similarly, the first electrical contact 191 and the second electrical contact 192 are recessed from the upper surface 122 of the frame 120 by approximately 2 mm. Similarly, the heating element 130 and the first electrical contact and the second electrical contact are recessed from the lower surface of the frame 120.

[0369] The heater assembly 100 is configured to be coupled to the wicking element so that the wicking element is in direct contact with one side of the heating element 130. The other side of the heating element 130 may then be exposed to air.

[0370] When current passes through the heating element 130, or when a non-zero voltage is applied between the first electrical contact 191 and the second electrical contact 192, the heating element 130 becomes hot due to resistive heating. The current passes through the continuous electrical path formed by the heating element 130 in a serpentine direction defined by the shape of the heating element 130. Since the first width is greater than the second width, and the heating portion 131 and the attachment portion 132 have substantially equal thicknesses perpendicular to the first plane, the cross-sectional area of ​​each heating portion 131 perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of ​​each attachment portion 132 perpendicular to the direction of the continuous electrical path. Therefore, when current passes through the heating element 130, or when a non-zero voltage is applied between the first electrical contact 191 and the second electrical contact 192, the temperature of the heating portion 131 will increase more than the temperature of the attachment portion 132.

[0371] The effect of increasing the temperature of the heating portion 131 more than the temperature of the attachment portion 132 may be achieved in alternative ways. For example, the thickness of the heating portion and the attachment portion may be different.

[0372] Figure 2A A perspective view of a heater assembly 200 according to another embodiment is shown. The frame 220 and the aperture 221 are Figures 1A-1C The frame and aperture shown in FIG. are the same. As in the first embodiment, the heater assembly 200 includes a heating element 230, which includes a plurality of heating portions 231 and at least one attachment portion 232. As in the first embodiment, the heater assembly 200 also includes a first electrical contact 291 and a second electrical contact 292. This embodiment is different from Figure 1AThe embodiment of FIG. 2 differs in that the heating element 230 further comprises at least one thermally insulating portion 235. Figure 2A In the embodiment shown in , the heating element 230 includes six thermal insulation portions 235. The number of thermal insulation portions 235 is equal to the number of attachment portions 232. Each of the thermal insulation portions 235 is connected between the frame 220 and one of the attachment portions 232. In particular, in the second embodiment, the frame 120 is overmolded on a section of each of the thermal insulation portions 235. Therefore, each attachment portion 232 is separated from the frame by one thermal insulation portion 235. Figure 2A In the embodiment shown in , a plurality of heating portions 231, at least one attachment portion 232 and at least one thermal insulation portion 235 are integrally formed and comprise stainless steel. A plurality of heating portions 231, at least one attachment portion 232 and at least one thermal insulation portion 235 have substantially equal thickness perpendicular to the first plane.

[0373] Figure 2B Shows Figure 2A A plan view of the heater assembly. Figure 1A As in the embodiment of the present invention, the heating portion 231 is shown as having a first width 241 in the first direction, and the attachment portion is shown as also having a second width 242 in the first direction. The second width is greater than the first width. In this second embodiment, the thermal isolation portion 235 has a third width in the first direction. The second width is greater than the third width. The third width is approximately 0.75 mm. Therefore, the ratio of the third width to the second width is approximately 1 / 2. In the embodiment shown, the third width is greater than the first width, but this may not always be the case. For example, the third width can be approximately equal to the first width or less than the first width. The thickness of the multiple heating portions 231, at least one attachment portion 232, and at least one thermal isolation portion 235

[0374] When current passes through the heating element 230, or when a non-zero voltage is applied between the first electrical contact 291 and the second electrical contact 292, the heating portion 231 and the attachment portion 232 heat up due to resistive heating. Although the temperature of the attachment portion 232 increases less than the temperature of the heating portion 231, as described with respect to Figures 1A-1C As described above, the attachment portion 232 may reach a temperature at which direct contact between the attachment portion 232 and the frame 220 is undesirable. Since the third width of the thermal isolation portion 235 is less than the second width of the attachment portion 232, the amount of energy transferred from the attachment portion to the frame 220 when current passes through the heating element 230 is less than if the attachment portion 232 is instead attached to the frame 220, such as in the first embodiment.

[0375] Figure 3AA perspective view of a heater assembly according to yet another embodiment is shown. The frame 320 and the aperture 321 are Figures 1A-1C The frame and apertures are the same as those shown in 2A-2B. As in the first and second embodiments, the heater assembly 300 includes a heating element 330, which includes a plurality of heating portions 331 and at least one attachment portion 332. Figure 1A -C and Figure 2A and 2B As in the embodiment of FIG. 1 , the heater assembly 300 further includes a first electrical contact 391 and a second electrical contact 392. This additional embodiment is similar to Figure 1A The embodiment differs in the shape of the heating element 330, which can also be Figure 3B Seen in.

[0376] Figure 3B A side view of a heater assembly according to yet another embodiment is shown. The plurality of heating portions 331 each include a radius of curvature orthogonal to the first plane. The outer surface of the curved heating portion 331 is configured to couple to a wicking element.

[0377] The attachment section of the attachment portion 332 and the sections of the first electrical contact 391 and the second electrical contact 392 are recessed from the upper surface 322 of the frame 320 by approximately 2 millimeters. Similarly, the attachment section of the attachment portion 332 and the sections of the first electrical contact 391 and the second electrical contact 392 are recessed from the lower surface of the frame 320. The attachment portion 332 and the first electrical contact 391 and the second electrical contact 392 include two sets of approximately ninety-degree bends. The first set of approximately ninety-degree bends 336 orient the attachment portion 332 and the first electrical contact 391 and the second electrical contact 392 so that they extend perpendicular to the first plane. The second set of approximately ninety-degree bends 337 orient the attachment portion 332 and the first electrical contact 391 and the second electrical contact 392 away from being perpendicular to the first plane. Thus, two sets of approximately ninety degree bends are arranged such that the plurality of heating portions 331 intersect the upper surface 322 of the frame 320, and at least a portion of each heating portion 331 extends beyond the plane formed by the upper surface 322 of the frame 320. In this further embodiment, the heating element is bent by cold stamping or micro bending.

[0378] Figure 4AA perspective view of a heater assembly according to yet another embodiment is shown. As in the previously described embodiments, the heater assembly 400 includes a heating element 430, which includes a plurality of heating portions 431 and at least one attachment portion 432. As in the previously described embodiments, the heater assembly 400 also includes a first electrical contact 491 and a second electrical contact 492. Compared to the first embodiment, in this yet another embodiment, the heater assembly 400 also includes a support structure 460. The frame 420 surrounds the support structure 460 in a first plane. The support structure 460 can be considered to be located within the aperture of the frame 420. The frame 420 includes a circular perimeter and a generally oval aperture. The support structure 460 includes a generally oval perimeter having the same size and shape as the generally oval aperture of the frame, so that the gap between the frame 420 and the support structure 460 is minimized. The support structure 460 includes a generally oval support structure aperture 461 in the first plane. The support structure 460 includes an upper support structure surface 462 that is parallel to the first plane and coplanar with the upper surface 422 of the frame 420. The plurality of heating portions 431 are coplanar with the upper support structure surface 462 and overlie the support structure apertures 461.

[0379] Figure 4B Shows Figure 4A 460. A perspective view of a heater assembly of FIG. 420, wherein selected components of the heater assembly are shown as transparent. In particular, the frame 420 and the support structure 460 are shown as transparent. Each attachment portion 432 includes a first section 433 and a second section 434. Each first section 433 is located on the upper support structure surface 462, and can therefore be considered to be coplanar with the upper support structure surface 462. Each attachment portion 432 also includes a first group of approximately ninety degree bends 437. This first group of ninety degree bends orients each second section 434 so that each second section 434 extends from the upper support structure surface 462 perpendicular to the upper support structure surface 462. Therefore, each second section 434 is positioned between the frame 420 and the support structure 460.

[0380] In addition, both the first electrical contact 491 and the second electrical contact 492 include a first electrical contact section 493, a second electrical contact section 494, and a third electrical contact section 495. In a similar manner to the attachment portion 432, the two first electrical contact sections 493 are substantially coplanar with the upper support structure surface 462. Both the first electrical contact 491 and the second electrical contact 492 also include two approximately ninety-degree bends 497, 496. The first pair of ninety-degree bends 497 orient the two second electrical contact sections 494 so that the two second electrical contact sections 494 extend perpendicularly from the upper support structure surface 462. Thus, the two second electrical contact sections 494 are positioned between the frame 420 and the support structure 460. The second pair of ninety-degree bends 498 orient the third electrical contact section 495 so that the third electrical contact section 495 is coplanar with the lower surface of the frame and parallel to the first plane. In this embodiment, the heating element is bent by cold stamping or microbending.

[0381] Figure 5 A schematic diagram of a cross-section of an aerosol generating device 510 is shown, the aerosol generating device comprising a heater assembly 500 according to any of the preceding embodiments.

[0382] The aerosol generating device 510 is an electrically operated smoking device, commonly referred to as an electronic cigarette system. The aerosol generating device 510 is a handheld, portable device and is about the size of a conventional cigar or cigarette.

[0383] The device 510 includes a battery 511 , such as a lithium iron phosphate battery, and a controller 512 electrically connected to the battery 511 .

[0384] The device 510 includes a housing 517. The housing contains a battery 511 and a controller 512. The device 510 is configured to be coupled to a cartridge comprising a wicking element and an aerosol-forming substrate. The device 510 includes a cartridge coupling portion 518 extending from a proximal end of the device 510. The cartridge coupling portion 518 extends annularly from the housing 517 and provides a cavity into which the cartridge can be received.

[0385] The heater assembly 500 includes a fluid permeable heating element 530 and a frame 520, both of which are as described in the previous embodiments. First and second electrical contacts (not shown) are electrically connected to the heating element 530, the battery 511, and the controller 512.

[0386] Device 510 includes device air inlet 513 and device air outlet 514. Device air inlet 513 is defined in the side wall of device 610. Device air outlet is defined in the proximal end of device. Device 510 includes device airflow passage 519. Device airflow passage 519 is defined between device air inlet 513 and device air outlet 514. Heating element 530 is positioned downstream of device air inlet 513 and upstream of device air outlet 514, and is in fluid communication with device airflow passage 519. In particular, the lower side of heating element 530 is in fluid communication with device airflow passage 519. It can be seen that device airflow passage 519 includes heater assembly airflow passage. Heater assembly airflow passage is defined between heater assembly air inlet and heater assembly air outlet. In the illustrated embodiment, device air outlet 514 includes heater assembly air outlet.

[0387] The device 510 also includes a spring element 516. The spring element 516 is fixed relative to the housing 517 and is in contact with the heater assembly 500.

[0388] Figure 6 A schematic diagram showing a cross-section of an aerosol generating system, the aerosol generating system comprising a Figure 5 The aerosol generating device and the cartridge connected to the aerosol generating device.

[0389] The cartridge 660 is coupled to the device 610 via the cartridge coupling portion 618. The cartridge 660 includes a liquid aerosol-forming substrate 662 and a ceramic wicking element 669 in a reservoir 661. In this system, the reservoir 661 is in fluid communication with the ceramic wicking element 669 so that the liquid aerosol-forming substrate 662 can flow from the reservoir 661 to the wicking element 669. The wicking element 669 includes a capillary material having a fiber or sponge structure. The wicking element 669 also forms a portion of the outer surface of the cartridge 660.

[0390] When the device 610 is coupled to the cartridge 660, the device air outlet 614 is configured to align with the cartridge air inlet 663. When the device 610 is coupled to the cartridge 660, the device airflow passage 619 is connected to the cartridge airflow passage 668, thereby defining a system airflow passage from the device air inlet 613 to the cartridge air outlet 664. The cartridge includes a mouthpiece 665, and the cartridge air outlet 664 is defined in the mouthpiece 665.

[0391] The wicking element 669 is configured to align with an aperture of the frame of the heater assembly. In this particular embodiment, when the system includes a heater assembly according to the first embodiment, the aperture is approximately 100 mm. 2The wicking element 669 also has a substantially square cross-sectional area with substantially the same cross-sectional area so that the wicking element 669 can be easily received by the aperture of the frame of the heater assembly. When the cartridge 660 is coupled to the device 610, the distal end of the wicking element contacts the upper side of the heating element 630.

[0392] The device 610 also includes a spring element 616. The spring element 616 is fixed relative to the device housing 617 and is in contact with the heater assembly 600. When the user couples the cartridge 650 to the device 610, the spring element 617 applies a force to the heater assembly 600. The force applied to the heater assembly 600 ensures good contact between the upper side of the heating element 630 and the wicking element 669.

[0393] In use, the user draws on the mouthpiece of the tube 665, thereby drawing air into the device air inlet 613. The system 650 is suction-activated, which means that a suction sensor (not shown) is located in the system 650, which can be a pressure sensor or an airflow sensor. In particular, the suction sensor will be positioned to be in fluid communication with the system airflow path, and preferably in or adjacent to the device airflow path 619. The suction sensor will detect the user's suction and send a signal to the controller 612, which causes the battery 611 to supply power to the heating element 630 of the heater assembly via the first electrical contact and the second electrical contact. This causes current to flow through the heating element 630, thereby resistively heating the heating element 630. In other examples, the aerosol generating system 650 may include a button that the user presses to send a signal to the controller 612 to supply power from the battery 611 to the heating element 630.

[0394] When the heating element 630 is heated, it heats the wicking element 669, and thereby heats any aerosol-forming substrate 662 contained in the wicking element 669. The heating of the wicking element 669 causes the aerosol-forming substrate 662 to vaporize.

[0395] When the user draws suction on the tube air outlet 664, air is sucked into the device air inlet 613. When air is drawn through the air passage, air will pass through the heater assembly. Air will flow through the lower side of the heating element 630, flow through the surface of the wicking element 669 and flow to the tube air outlet 664. The evaporated aerosol forms a substrate 662 entrained in the flowing air. Then, the entrained steam cools and condenses to form an aerosol. Aerosol leaves the device airflow passage 619 through the air outlet 614. Then the aerosol enters the tube 660 through the tube air inlet 663, leaves the tube 660 through the tube air outlet 664, and is delivered to the user's mouth.

[0396] As the liquid aerosol-forming substrate 662 in the wicking element 669 is heated, vaporized and entrained in the airflow, the liquid aerosol-forming substrate 662 from the reservoir 661 travels into the wicking element 669. This aerosol-forming substrate 662 from the reservoir 661 effectively replaces the vaporized aerosol-forming substrate 662. Since the wicking element 669 is a capillary material having a fiber or sponge structure, the liquid aerosol-forming substrate 662 from the reservoir 661 may be drawn into the wicking element 669 at least partially by capillary action.

[0397] After multiple uses of the aerosol generating system 650, the wicking element 669 may begin to degrade, or the reservoir 661 may be drained of the aerosol-forming substrate 662. The user may then separate the cartridge 660 from the device 610. The cartridge 660 may be removed and disposed of. The aerosol generating device 610 may then be reused with a new cartridge.

[0398] Figure 7 A schematic diagram showing a cross section of a cartridge 760 according to another embodiment, the cartridge 760 comprising a cartridge 760 according to reference Figures 1A to 4B The heater assembly 700 of any of the described embodiments.

[0399] Similar to Figure 6 The cartridge 660 shown in FIG. Figure 7 The cartridge 760 shown in FIG. 7 includes a liquid aerosol-forming substrate 762 and a ceramic wicking element 769 in a reservoir 761. In this system, the reservoir 761 is in fluid communication with the ceramic wicking element 769 so that the liquid aerosol-forming substrate 662 can flow from the reservoir 661 to the wicking element 669. The cartridge also includes a mouthpiece 765, and a cartridge air outlet 764 is defined in the mouthpiece 765.

[0400] and Figure 5 and 6 Compared to the embodiment shown in , the heater assembly 700 is located in the cartridge 760, rather than in the aerosol generating device. The heater assembly 700 is positioned so that the wicking element 769 is aligned with the aperture of the frame of the heater assembly 700, and so that the distal end of the wicking element 769 contacts the upper side of the heating element 730. In addition, the cartridge includes a cartridge air inlet 763 upstream of the heater assembly 700, so that the cartridge air flow path 768 is defined between the cartridge air inlet 763 and the cartridge air outlet 764, and the heating element 730 is in fluid communication with the cartridge air flow path 768.

[0401] The cartridge 760 is configured to be coupled to a suitable aerosol generating device comprising a battery (e.g., a lithium iron phosphate battery), a controller electrically connected to the battery, a first device electrical contact portion and a second device electrical contact portion, and a cartridge coupling portion providing a cavity into which the cartridge 760 can be received.

[0402] The cartridge 760 includes a first cartridge electrical contact portion and a second cartridge electrical contact portion (not shown), the first cartridge electrical contact portion and the second cartridge electrical contact portion being configured to contact a first device electrical contact portion and a second device electrical contact portion when the cartridge 760 is connected to a suitable device so that power can be supplied from the battery to the heating element 730.

[0403] For the purpose of this specification and the appended claims, unless otherwise stated, all numbers representing amounts, quantities, percentages, etc. should be understood to be modified by the term "about" in all cases. In addition, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically 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 percentages listed above, provided that the amount of A deviation will not substantially affect the basic features and novel features of the invention claimed for protection. In addition, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed in this article.

Claims

1. A heater assembly for an aerosol generating device, the heater assembly comprising: a heating element, wherein the heating element comprises a plurality of heating portions and at least one attachment portion, a support structure comprising a support structure aperture and an upper support structure surface parallel to the first plane, a frame at least partially surrounding the support structure, a first electrical contact in electrical contact with the first end of the heating element, and a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact, wherein the heating element is fixed to the frame, and wherein each heating portion is within or overlying the support structure aperture and is separated from the frame by at least one attachment portion, wherein each attachment portion comprises a first section and a second section, wherein each first section is substantially parallel to the first plane, and each second section extends from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface, wherein both the first electrical contact and the second electrical contact comprise a first electrical contact section and a second electrical contact section, and Two first electrical contact sections are substantially parallel to the first plane, and two second electrical contact sections extend from the upper support structure surface toward the second plane. 2 . The heater assembly of claim 1 , wherein each second segment extends in a direction perpendicular to the surface of the upper support structure.

3. The heater assembly of claim 1 or 2, wherein at least a portion of the heating element is coplanar with the upper support structure surface.

4. The heater assembly of claim 3, wherein the plurality of heating portions are coplanar with the upper support structure surface.

5. A heater assembly according to any preceding claim, wherein each second section is secured between the frame and the support structure.

6. A heater assembly according to any preceding claim, wherein the plurality of heating portions and the at least one attachment portion are all integrally formed.

7. A heater assembly according to any preceding claim, wherein when the direction of the continuous electrical path is defined by each heating portion, each heating portion has a first width in a first direction perpendicular to the direction of the continuous electrical path, and each attachment portion has a second width in the first direction, and wherein the second width is greater than the first width.

8. A heater assembly according to any preceding claim, wherein the frame is electrically insulating.

9. The heater assembly of claim 8, wherein the frame has a thermal conductivity of 1 W / mK or less.

10. A heater assembly according to any preceding claim, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the plurality of heating portions increases more than the temperature of the at least one attachment portion.

11. A heater assembly according to any preceding claim, wherein the heating element is serpentine in shape.

12. An aerosol generating device comprising a heater assembly, the heater assembly comprising: a heating element, wherein the heating element comprises a plurality of heating portions and at least one attachment portion, a support structure comprising a support structure aperture and an upper support structure surface parallel to the first plane, a frame at least partially surrounding the support structure, a first electrical contact in electrical contact with the first end of the heating element, and a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact, wherein the heating element is fixed to the frame, and wherein each heating portion is within or overlying the support structure aperture and is separated from the frame by at least one attachment portion, wherein each attachment portion comprises a first section and a second section, wherein each first section is substantially parallel to the first plane, and each second section extends from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface, wherein both the first electrical contact and the second electrical contact comprise a first electrical contact section and a second electrical contact section, and wherein two first electrical contact sections are substantially parallel to the first plane, and two second electrical contact sections extend from the upper support structure surface toward the second plane; an air flow passage defined between the air inlet and the air outlet, the air flow passage being in fluid communication with the heating element, a power source in electrical contact with the first electrical contact and the second electrical contact and configured to supply power to the heating element, and A control circuit is configured to control the supply of power from the power source to the heating element.

13. An aerosol generating system comprising: A cartridge, comprising: an aerosol-forming substrate in fluid communication with the wicking material, wherein the wicking material forms part of the outer surface of the barrel, and An aerosol generating device, the aerosol generating device comprising: A heater assembly, the heater assembly comprising: a heating element, wherein the heating element comprises a plurality of heating portions and at least one attachment portion, a support structure comprising a support structure aperture and an upper support structure surface parallel to the first plane, a frame at least partially surrounding the support structure, a first electrical contact in electrical contact with the first end of the heating element, and a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact, wherein the heating element is fixed to the frame, and wherein each heating portion is within or overlying the support structure aperture and is separated from the frame by at least one attachment portion, wherein each attachment portion includes a first segment and a second segment, and wherein each first segment is substantially parallel to the first plane, and each second segment extends from the upper support structure surface toward a second plane, the second plane being parallel but not coplanar with the upper support structure surface; an air flow passage defined between the air inlet and the air outlet, the air flow passage being in fluid communication with the heating element, a power source in electrical contact with the first electrical contact and the second electrical contact and 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 heating element, wherein the cartridge is reversibly coupleable to the aerosol generating device such that when the cartridge is coupled to the device, the wicking material is in direct contact with the heating element.

14. A cartridge for an aerosol generating system, the cartridge comprising: an aerosol-forming substrate in fluid communication with the wicking material, as well as A heater assembly, the heater assembly comprising: a heating element, wherein the wicking material is in contact with the heating element, and wherein the heating element comprises a plurality of heating portions and at least one attachment portion, a support structure comprising a support structure aperture and an upper support structure surface parallel to the first plane, a frame at least partially surrounding the support structure, a first electrical contact in electrical contact with the first end of the heating element, and a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact, wherein the heating element is fixed to the frame, and wherein each heating portion is within or overlying the support structure aperture and is separated from the frame by at least one attachment portion, wherein each attachment portion comprises a first section and a second section, wherein each first section is substantially parallel to the first plane, and each second section extends from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface, wherein both the first electrical contact and the second electrical contact comprise a first electrical contact section and a second electrical contact section, and Two first electrical contact sections are substantially parallel to the first plane, and two second electrical contact sections extend from the upper support structure surface toward the second plane.

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