Retainer assembly for cartridge of aerosol-generating system

Abstract

A holder assembly (15) for a cartridge (10) of an aerosol-generating system (100) is provided. The holder assembly (15) comprises a susceptor assembly (12) comprising a wicking element (18) and a susceptor element (16). The wicking element (18) has a planar shape and comprises a first side portion (33), a second side portion (35), and a central portion (31) extending between the first side portion (33) and the second side portion (35). A susceptor element (16) extends around at least a portion of the central portion (31) of the wicking element (18). The retainer assembly (15) also includes a retainer (14) defining an airflow channel (26). The retainer (14) includes a first slot (28) and a second slot (29) opposite the first slot (28). The first side portion (33) of the wicking element (18) is received within the first slot (28) and the second side portion (35) of the wicking element (18) is received within the second slot (29). The central portion (31) of the wicking element (18) and the susceptor element (16) are positioned within the airflow channel (26).

Description

[0001] The present disclosure relates to a holder assembly for a cartridge of an aerosol generating system. The present disclosure also relates to a method of manufacturing a holder assembly for a cartridge of an aerosol generating system.

[0002] Aerosol generating systems configured to generate inhalable aerosols from liquid aerosol-forming substrates are known in the art. It is also known that such systems use induction heating mechanisms to generate heat for evaporating aerosol-forming substrates. Induction heating mechanisms generally include an inductor coil arranged around a susceptor element. In the case where the aerosol-forming substrate is a liquid aerosol-forming substrate, a wicking element can be provided to transport liquid from a reservoir of the liquid aerosol-forming substrate toward the susceptor element. The alternating current generated by the inductor coil generates a changing magnetic field, which induces eddy currents in the susceptor element, thereby heating the susceptor element. The heat from the susceptor element causes the liquid aerosol-forming substrate from the wicking element near the susceptor element to evaporate. The airflow through the susceptor element entrains vapor. The entrained vapor cools and condenses to form an aerosol, for the user to inhale.

[0003] It would be desirable to improve the heating of a liquid aerosol-forming substrate by a susceptor element whilst also facilitating the manufacture of systems comprising the susceptor element.

[0004] According to a first aspect of the present disclosure, a holder assembly for a cartridge of an aerosol generating system is provided. The holder assembly may include a susceptor assembly. The susceptor assembly may include a wicking element. The susceptor assembly may include a susceptor element. The wicking element may have a planar shape. The wicking element may include a first side portion, a second side portion, and a central portion extending between the first side portion and the second side portion. The susceptor element may extend around at least a portion of the central portion of the wicking element. The holder assembly may include a holder defining an airflow channel. The holder may include a first slot and a second slot opposite to the first slot. The first side portion of the wicking element may be received in the first slot. The second side portion of the wicking element may be received in the second slot. The central portion of the wicking element and the susceptor element may be positioned in the airflow channel.

[0005] According to a second aspect of the present disclosure, a holder assembly for a cartridge of an aerosol generating system is provided. The holder assembly includes a susceptor assembly, which includes a wicking element and a susceptor element. The wicking element has a planar shape and includes a first side portion, a second side portion, and a central portion extending between the first side portion and the second side portion. The susceptor element extends around at least a portion of the central portion of the wicking element. The holder assembly also includes a holder defining an airflow channel. The holder includes a first slot and a second slot opposite to the first slot. The first side portion of the wicking element is received in the first slot, and the second side portion of the wicking element is received in the second slot. The central portion of the wicking element and the susceptor element are positioned in the airflow channel.

[0006] Advantageously, providing a wicking element having a planar shape may increase or maximise the surface area of ​​the wicking element compared to other shapes.Advantageously, increasing or maximising the surface area of ​​the wicking element may improve or maximise evaporation of the liquid aerosol-forming substrate from the wicking element.

[0007] Advantageously, providing a susceptor element around the central portion of the wicking element can reduce or minimize heat transfer from the susceptor element to the retainer. Advantageously, this can increase or maximize heating of the wicking element by the susceptor element. Preferably, the susceptor element extends only around the central portion of the wicking element. In other words, preferably, the susceptor element does not contact the first side portion of the wicking element, the second side portion of the wicking element, or the retainer.

[0008] Advantageously, positioning the first and second side portions of the wicking element in the first and second slots on the holder can facilitate the correct positioning of the central portion of the wicking element and the susceptor element in the airflow channel. Advantageously, the first and second slots can facilitate the manufacture of the holder assembly by inserting the first and second side portions of the wicking element into the first and second slots, respectively. Advantageously, the first and second slots can facilitate the transfer of the liquid aerosol-forming substrate to the central portion of the wicking element through the first and second side portions of the wicking element.

[0009] As used herein, the term "aerosol generating device" is used to describe a device that interacts with an aerosol-forming substrate to generate an aerosol. Preferably, the aerosol generating device is a smoking device that interacts with an aerosol-forming substrate to generate an aerosol that can be inhaled directly into the user's lungs through the user's mouth. The aerosol-forming substrate may form part of a cartridge or an aerosol-generating article configured for engagement with an aerosol generating device.

[0010] As used herein, the term "aerosol" refers to a dispersion of solid particles or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. An aerosol may be visible or invisible. An aerosol may include vapors of a substance that is normally liquid or solid at room temperature, as well as solid particles or liquid droplets, or a combination of solid particles and liquid droplets.

[0011] As used herein, the term "aerosol-forming substrate" refers to a substrate consisting of or comprising an aerosol-forming material which is capable of releasing volatile compounds to generate an aerosol when heated.

[0012] As used herein, "susceptor element" means an element that can be heated by the penetration of a varying magnetic field. The susceptor element is generally heatable by at least one of Joule heating and hysteresis losses through eddy currents induced in the susceptor element.

[0013] Preferably, only the first side portion of the wicking element is received in the first slot, and only the second side portion of the wicking element is received in the second slot. In other words, preferably, other components of the retainer assembly are not received in the first slot and the second slot. Advantageously, positioning only the first side portion of the wicking element in the first slot and only the second side portion of the wicking element in the second slot can facilitate the seal between the wicking element and the retainer. Advantageously, the seal between the wicking element and the retainer can reduce or prevent the liquid aerosol-forming matrix from leaking into the airflow channel between the first slot and the first side portion of the wicking element and between the second slot and the second side portion of the wicking element.

[0014] The retainer may include a tubular portion that at least partially defines an airflow channel, wherein the first slot and the second slot are defined by the tubular portion. Preferably, the first slot and the second slot are positioned on opposite sides of the airflow channel. Advantageously, positioning the first slot opposite to the second slot may facilitate central positioning of the susceptor assembly within the airflow channel. Advantageously, positioning the first slot opposite to the second slot may facilitate insertion of the first side portion and the second side portion of the planar wicking element into the first slot and the second slot, respectively, during manufacture of the retainer assembly.

[0015] The airflow channel may define a longitudinal direction extending between a first end of the airflow channel and a second end of the airflow channel.

[0016] Preferably, the planar shape of the wicking element extends parallel to the longitudinal direction. Advantageously, positioning the planar shape of the wicking element parallel to the longitudinal direction can position the planar shape of the wicking element parallel to the airflow through the airflow channel during use. Advantageously, the parallel airflow can increase or maximize the flow of evaporated liquid aerosol-forming substrate away from the susceptor assembly. Advantageously, the parallel airflow can reduce or minimize the suction resistance through the airflow channel during use.

[0017] Preferably, each of the first and second slots has an elongated shape extending in the longitudinal direction. Advantageously, providing each of the first and second slots with an elongated shape extending in the longitudinal direction can facilitate positioning the planar shape of the wicking element parallel to the airflow through the airflow channel during use.

[0018] The first slot may have at least one of a different size and a different shape than the second slot. Advantageously, providing the first slot and the second slot with at least one of a different size and a different shape may facilitate insertion of the susceptor assembly into the airflow channel through one of the first slot and the second slot during manufacture of the retainer assembly.

[0019] Preferably, each of the first slot and the second slot has a length and a width extending perpendicular to the length. The length of the second slot may be greater than the length of the first slot. The width of the second slot may be greater than the width of the first slot. Advantageously, providing the second slot with at least one of a larger length and a larger width may facilitate insertion of the susceptor assembly into the airflow channel through the second slot. For example, due to the additional presence of the susceptor element, the thickness of the susceptor assembly may be greater at the central portion of the wicking element. Therefore, the first slot may be sized to receive only the first side portion of the wicking element. The second slot may be sized to allow the central portion of the wicking element and the susceptor element to pass through the second slot during manufacture of the retainer assembly.

[0020] Preferably, the length of each of the first and second slots extends in the longitudinal direction. Advantageously, providing each of the first and second slots with a length extending in the longitudinal direction can facilitate positioning the planar shape of the wicking element parallel to airflow through the airflow channel during use.

[0021] Preferably, the shape of the first slot is the same as the cross-sectional shape of the first side portion of the wicking element.The first slot may have a rectangular shape.The first slot may have a rounded rectangular shape.

[0022] The second slot may have the same shape as the first slot. The second slot may have the same shape as the cross-sectional shape of the second side portion of the wicking element. The second slot may have the same shape as the cross-sectional shape of the central portion of the wicking element and the susceptor element of the susceptor assembly. The second slot may have a rectangular shape. The second slot may have a rounded rectangular shape.

[0023] The second slot may include an elongated portion and an enlarged portion at one end of the elongated portion. Advantageously, in embodiments where the susceptor assembly is inserted into the airflow channel through the second slot during manufacture of the holder assembly, the enlarged portion may facilitate passage of a portion of the susceptor element through the second slot. For example, the enlarged portion may facilitate passage of a fold, joint, or seam of the susceptor element through the second slot.

[0024] The elongated portion of the second slot may have a rectangular shape. The elongated portion of the second slot may have a rounded rectangular shape.

[0025] The enlarged portion of the second slot may have a circular shape.

[0026] During the use of the holder assembly in a cartridge with an aerosol generating system, air can flow through the airflow channel from the first end to the second end. Preferably, the enlarged portion of the second slot is positioned closer to the second end of the airflow channel than the elongated portion of the second slot. In other words, preferably, the enlarged portion of the second slot is downstream of the elongated portion of the second slot. Advantageously, positioning the enlarged portion at the downstream end of the second slot can facilitate positioning the fold, joint or seam of the susceptor element at the downstream end of the susceptor assembly. Advantageously, positioning the fold, joint or seam of the susceptor element at the downstream end of the susceptor element can reduce or eliminate interference of the airflow to the fold, joint or seam during use.

[0027] Preferably, the susceptor assembly has a planar shape including a first planar surface and a second planar surface opposite the first planar surface. The susceptor assembly may have a thickness extending between the first planar surface and the second planar surface. The thickness of the susceptor assembly may be greater at a central portion of the wicking element than each of a first side portion of the wicking element and a second side portion of the wicking element.

[0028] Preferably, the susceptor assembly has an upstream end and a downstream end, the upstream end and the downstream end being arranged so that air flows through the susceptor assembly from the upstream end to the downstream end during use of the holder assembly in a cartridge having an aerosol generating system. The thickness of the susceptor assembly at the central portion of the wicking element may be greater at the downstream end than at the upstream end. For example, the thickness of the susceptor assembly may be greater at the downstream end due to a fold, joint or seam of the susceptor element.

[0029] The retainer may include a first retainer portion and a second retainer portion connected to the first retainer portion, wherein each of the first slot and the second slot is partially defined by the first retainer portion and partially defined by the second retainer portion. Advantageously, each of the first slot and the second slot being partially defined by the first retainer portion and the second retainer portion can facilitate the insertion of the sensor assembly into the retainer during the manufacture of the retainer assembly. For example, the first side portion and the second side portion of the wicking element can be inserted into the partial slot defined by the first retainer portion or the second retainer portion before the first retainer portion and the second retainer portion are connected to each other. In this way, when the first slot and the second slot are formed during the connection of the first retainer portion and the second retainer portion to each other, the first side portion and the second side portion of the wicking element can be automatically received in the first slot and the second slot.

[0030] Each of the first retainer portion and the second retainer portion may have a tubular shape. The first retainer portion and the second retainer portion may be connected to each other at a position between the first end and the second end of the airflow channel. Each of the first retainer portion and the second retainer portion may include an upstream end and a downstream end, wherein the upstream end of the second retainer portion is connected to the downstream end of the first retainer portion. The first retainer portion may define an upstream portion of the first slot and an upstream portion of the second slot. The second retainer portion may define a downstream portion of the first slot and a downstream portion of the second slot.

[0031] Each of the first retainer portion and the second retainer portion may extend between a first end of the airflow channel and a second end of the airflow channel. The first retainer portion and the second retainer portion may be connected to each other along one or more joints extending between the first end of the airflow channel and the second end of the airflow channel. Each of the first retainer portion and the second retainer portion may have a semi-tubular shape.

[0032] The second retainer part may be connected to the first retainer part by an interference fit.

[0033] The retainer may comprise a retaining portion arranged to secure the second retainer portion to the first retainer portion.The retaining portion may engage with at least one of the first retainer portion and the second retainer portion by an interference fit.

[0034] The retaining portion may be integrally formed with the first retainer portion or the second retainer portion. The retaining portion may be integrally formed with the first retainer portion and engage with the second retainer portion by an interference fit. The retaining portion may be integrally formed with the second retainer portion and engage with the first retainer portion by an interference fit.

[0035] The holding portion may be formed separately from the first retainer portion and the second retainer portion. The holding portion may engage with both the first retainer portion and the second retainer portion by an interference fit. The holding portion may have an annular shape. The holding portion may extend around a portion of the first retainer portion and a portion of the second retainer portion.

[0036] The retainer can have a tubular shape including a first end and a second end. Each of the first slot and the second slot can extend from the first end of the retainer so that each of the first slot and the second slot is open at the first end of the retainer. Advantageously, the open ends of the first slot and the second slot can facilitate the manufacture of the retainer assembly. For example, the first side portion and the second side portion of the wicking element can be simultaneously inserted into the first slot and the second slot through the open ends of the slots, respectively.

[0037] Each of the first and second slots may include an insertion portion extending from the first end of the retainer and a retaining portion extending from the insertion portion. Advantageously, the insertion portion may facilitate insertion of a side portion of the wicking element into the slot.

[0038] Preferably, each insert portion has a larger cross-sectional dimension than the corresponding retaining portion. Preferably, each insert portion has a tapered shape. Preferably, each insert portion has a cross-sectional dimension that decreases in size in a direction along the retainer from the first end.

[0039] Preferably, each retaining portion has a constant cross-sectional size in a direction along the retainer from the first end. Advantageously, providing each retaining portion with a constant cross-sectional size may facilitate retaining the side portion of the wicking element in the slot.

[0040] Preferably, the first side portion of the wicking element and the second side portion of the wicking element are received only within the retaining portions of the first slot and the second slot, respectively. In other words, preferably, the insertion portions of the first slot and the second slot are only used to facilitate the insertion of the side portions of the wicking element into the retaining portions of the first slot and the second slot.

[0041] The holder assembly may include a cover connected to a first end of the holder, wherein the cover is arranged to close each of the first slot and the second slot at the first end of the holder. Advantageously, closing the ends of the first slot and the second slot at the first end of the holder may facilitate retaining the first side portion and the second side portion of the wicking element in the first slot and the second slot.

[0042] In embodiments where each of the first slot and the second slot has an insert portion, preferably the cover is arranged to block and seal the insert portion of each of the first slot and the second slot. Advantageously, blocking and sealing the insert portion of each of the first slot and the second slot may reduce or prevent leakage of the liquid aerosol-forming substrate through the insert portion of the first slot and the second slot into the airflow channel.

[0043] Preferably, the cover is connected to the retainer by an interference fit.

[0044] Preferably, the first side portion of the wicking element is received in the first slot by an interference fit, and the second side portion of the wicking element is received in the second slot by an interference fit. Advantageously, retaining the wicking element in the first slot and the second slot using an interference fit can simplify the manufacture of the retainer assembly. Advantageously, retaining the wicking element in the first slot and the second slot using an interference fit can facilitate sealing between the wicking element and the retainer at each of the first slot and the second slot.

[0045] Preferably, the susceptor element comprises at least one strip of susceptor material having an annular shape and extending around a central portion of the wicking element.

[0046] The susceptor element may be formed of any suitable material. Suitable materials include at least one of graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, and other conductive materials. Advantageously, the susceptor element may be formed of a ferromagnetic material. Preferably, the susceptor element may be formed of AISI 430 stainless steel.

[0047] The susceptor element may have a relative permeability of between 1 and 40,000 when measured at a suitable frequency and temperature, for example when measured at a frequency of up to 10 kHz at a temperature of 20 degrees Celsius. When it is desired that most of the heating be dependent on eddy currents, a lower permeability material may be used, whereas when a hysteresis effect is desired, a higher permeability material may be used. Preferably, the material has a relative permeability of between 500 and 40,000. This may provide efficient heating of the susceptor element.

[0048] The susceptor element can be fluid permeable. As used herein, a "fluid permeable" element means an element that allows liquid or gas to pass through it. A fluid permeable susceptor element can advantageously allow evaporated aerosol-forming substrate to escape through the susceptor element. The susceptor element may include a net. As used herein, the term "net" encompasses grids and arrays of wires with spaces therebetween. The term net also includes woven fabrics and nonwoven fabrics. In use, when a mesh configuration is adopted for the susceptor element, evaporated aerosol-forming substrates can advantageously escape from the wicking element through gaps present in the susceptor element.

[0049] The wicking element may include a capillary material. The capillary material is a material that can transport liquid from one end of the material to the other end by means of capillary action. The capillary material may have a fibrous or spongy structure. The capillary material preferably includes a capillary bundle. For example, the capillary material may include a plurality of fibers or lines or other fine-pore tubes. In certain embodiments, the capillary material may include a spongy or foamy material. The structure of the capillary material may form a plurality of small holes or tubules, and the liquid aerosol-forming substrate may be transported through the plurality of small holes or tubules by capillary action. In the case where one or more strips include gaps, the capillary material may extend into the gaps. In use, the liquid aerosol-forming substrate may be sucked into the gaps by capillary action. The wicking element may include an electrically insulating material or be composed of an electrically insulating material. The wicking element may include a non-metallic material. The wicking element may include a hydrophilic material or a lipophilic material. This may advantageously promote the transport of the aerosol-forming substrate by the wicking element.

[0050] The wicking element may preferably include or consist of cotton, rayon or fiberglass.

[0051] The retainer can be formed of any suitable material or combination of materials. Preferably, the retainer is formed of a plastic or thermoplastic suitable for food or pharmaceutical applications. For example, the retainer can include at least one of polypropylene, polyetheretherketone (PEEK) and polyethylene. Preferably, the material is lightweight and non-brittle.

[0052] According to a third aspect of the present disclosure, a cartridge for an aerosol generating system is provided. The cartridge may include a retainer assembly according to the first aspect or the second aspect of the present disclosure. The cartridge may include a reservoir for a liquid aerosol-forming substrate. The reservoir may be in fluid communication with a first side portion of a wicking element and a second side portion of a wicking element through a first slot and a second slot, respectively.

[0053] According to a fourth aspect of the present disclosure, a cartridge for an aerosol generating system is provided. The cartridge comprises a retainer assembly according to any example or embodiment described herein according to the second aspect of the present disclosure. The cartridge also comprises a reservoir for a liquid aerosol-forming substrate. The reservoir is in fluid communication with a first side portion of a wicking element and a second side portion of a wicking element through a first slot and a second slot, respectively.

[0054] Preferably, the reservoir extends around at least a portion of the outer surface of the retainer. Preferably, the reservoir has an annular shape. The tube may include a tube outer shell extending around at least a portion of the retainer, wherein the reservoir is at least partially defined by the space between the outer surface of the retainer and the inner surface of the tube outer shell.

[0055] The cartridge may include a holding material contained in the reservoir, the holding material being used to hold the liquid aerosol forming substrate. The holding material may be a foam, sponge or a collection of fibers. The holding material may be formed of a polymer or a copolymer. The holding material may be a spinning polymer.

[0056] Preferably, the cartridge comprises a liquid aerosol-forming substrate contained in the reservoir. The liquid aerosol-forming substrate may include nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt substrate. The liquid aerosol-forming substrate may include a plant-based material. The liquid aerosol-forming substrate may include tobacco. The liquid aerosol-forming substrate may include a tobacco-containing material comprising volatile tobacco flavor compounds, which are released from the aerosol-forming substrate when heated. The liquid aerosol-forming substrate may include a homogenized tobacco material. The liquid aerosol-forming substrate may include a tobacco-free material. The liquid aerosol-forming substrate may include a homogenized plant-based material.

[0057] The liquid aerosol-forming matrix may include one or more aerosol formers. The aerosol former is any suitable known compound or mixture of compounds that promotes the formation of a dense and stable aerosol in use and is substantially resistant to thermal degradation at the operating temperature of the system. 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 mono-, di- or tri-acetates of glycerol; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The liquid aerosol-forming matrix may include water, solvents, ethanol, plant extracts and natural or artificial flavoring agents.

[0058] The liquid aerosol-forming substrate may include nicotine and at least one aerosol former. The aerosol former may be glycerol or propylene glycol. The aerosol former may include both glycerol and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration between about 0.5% and about 10%, for example about 2%.

[0059] Preferably, the cartridge includes a mouthpiece defining an air outlet, wherein the air outlet is in fluid communication with the downstream end of the airflow channel. The mouthpiece may be integrally formed with the retainer. The mouthpiece may be formed separately from the retainer and connected to the retainer. The mouthpiece may be connected to the retainer by an interference fit.

[0060] In the embodiment where the cartridge comprises a cartridge outer shell, the mouthpiece may be integrally formed with the cartridge outer shell. The mouthpiece may be formed separately from the cartridge outer shell and connected to the cartridge outer shell. The mouthpiece may be connected to the cartridge outer shell by an interference fit.

[0061] The upstream end of the air flow channel may form a cartridge air inlet. During use, air enters the cartridge through the cartridge air inlet, flows through the air flow channel, flows through the susceptor assembly, and leaves the cartridge through an air outlet defined by the mouthpiece. The vaporized liquid aerosol-forming substrate generated by the susceptor assembly is entrained in the air flow in the air flow channel. When the aerosol leaves the cartridge through the air outlet defined by the mouthpiece, the entrained vapor condenses to form an aerosol for inhalation by the user.

[0062] The tube may include at least one seal extending across a portion of the airflow channel. The tube may include an upstream seal extending across the tube air inlet. The upstream seal may be sealed to a retainer. The upstream seal may be sealed to the tube outer housing. The upstream seal may be sealed to both the retainer and the tube outer housing. The upstream seal may be fragile or removable. The upstream seal may be arranged to automatically rupture when the tube is inserted into the aerosol generating device.

[0063] The cartridge may include a downstream seal. The downstream seal may extend across an air outlet defined by the mouthpiece. The downstream seal may seal to the mouthpiece. The downstream seal may be frangible or removable.

[0064] In an embodiment where the mouthpiece is formed separately from the retainer, the downstream seal may extend across the downstream end of the airflow channel defined by the retainer. The downstream seal may be sealed to the retainer. The downstream seal may be sealed to the tube outer housing. The downstream seal may be sealed to both the retainer and the tube outer housing. The downstream seal may be fragile or removable. The downstream seal may be arranged to automatically break when the retainer is connected to the mouthpiece by the user.

[0065] In the embodiment that the tube comprises a cigarette holder, a tube outer shell or both a cigarette holder and a tube outer shell, each of the cigarette holder and the tube outer shell can be formed by any suitable material or a combination of materials. Preferably, the cigarette holder and the tube outer shell are formed by plastics or thermoplastics suitable for food or drug applications. For example, each of the cigarette holder and the tube outer shell can include at least one of polypropylene, polyetheretherketone (PEEK) and polyethylene. Preferably, the material is lightweight and non-brittle.

[0066] According to a fifth aspect of the present disclosure, an aerosol generating system is provided. The aerosol generating system may include the cartridge according to the third aspect or the fourth aspect of the present disclosure. The aerosol generating system may include an aerosol generating device. The aerosol generating device may include a device housing, the device housing defining a cavity, the cavity being used to receive at least a portion of the retainer assembly so that the receptor assembly is positioned in the cavity. The aerosol generating device may include an inductor coil, the inductor coil being arranged to generate a changing magnetic field in the cavity.

[0067] According to a sixth aspect of the present disclosure, an aerosol generating system is provided. The aerosol generating system comprises a cartridge according to the fourth aspect of the present disclosure according to any example or embodiment described herein. The aerosol generating system also comprises an aerosol generating device. The aerosol generating device comprises a device housing, the device housing defining a cavity, the cavity being used to receive at least a portion of a retainer assembly so that a receptor assembly is positioned within the cavity. The aerosol generating device also comprises an inductor coil, the inductor coil being arranged to generate a changing magnetic field within the cavity.

[0068] The inductor coil may comprise a flat spiral inductor coil.

[0069] The inductor coil may be wound around at least a portion of the cavity. The inductor coil may have a tubular shape or a helical shape. Preferably, the inductor coil is both tubular and helical. Preferably, tubular and helical coils have a non-circular cross-section when viewed in a direction perpendicular to the longitudinal length of the coil, i.e., in a direction perpendicular to the magnetic center axis of the coil. Preferably, the inductor coil is positioned so that when the holder assembly is received in the cavity, the susceptor assembly is positioned inside the inductor coil.

[0070] Preferably, the aerosol generating device comprises a power source.

[0071] The power supply can be a DC power supply. In some preferred embodiments, the power supply is a battery, such as a rechargeable lithium-ion battery. The power supply can be another form of charge storage device, such as a capacitor. The power supply may need to be recharged. The power supply can have a capacity that allows storage of enough energy for one or more uses of the device. For example, the power supply can have enough capacity to allow continuous generation of aerosol for a period of about six minutes, corresponding to the typical time consumed by smoking a conventional cigarette, or for a period of a multiple of six minutes. In another example, the power supply can have enough capacity to allow the use of a predetermined number of times of the device or discontinuous activation. In one embodiment, the power supply is a DC power supply with a DC power supply voltage in the range of about 2.5 volts to about 4.5 volts and a DC power supply current in the range of about 1 ampere to about 10 amperes (corresponding to a DC power supply in the range of about 2.5 watts to about 45 watts).

[0072] Preferably, the aerosol generating device comprises a controller.The controller may be arranged to supply a varying current from a power supply to the inductor coil.

[0073] The controller may include a microprocessor, which may be a programmable microprocessor, a microcontroller or an application specific integrated chip (ASIC) or other circuit capable of providing control. The controller may include other electronic components. The controller may be configured to regulate the current supply to the inductor coil. The current may be continuously supplied to the inductor coil after the aerosol generating device is activated, or may be supplied intermittently, such as on a puff-by-puff basis.

[0074] The controller may be configured to supply a current varying at a frequency between about 5 kilohertz and about 500 kilohertz to the inductor coil.

[0075] The controller may be configured to supply a high frequency varying current to the inductor coil. As used herein, the term "high frequency varying current" means a varying current having a frequency between about 500 kilohertz and about 30 megahertz. The high frequency varying current may have a frequency between about 1 megahertz and about 30 megahertz, such as between about 1 megahertz and about 10 megahertz, or such as between about 5 megahertz and about 8 megahertz.

[0076] The controller may advantageously comprise a DC / AC inverter.The DC / AC inverter may comprise a class C, class D or class E power amplifier.

[0077] The device housing can be elongated. The device housing can include any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of those materials, or thermoplastic materials suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK) and polyethylene. Preferably, the material is lightweight and non-brittle.

[0078] The device housing may include an air inlet. The air inlet may be configured to allow ambient air to enter the device housing. Preferably, the air inlet is in fluid communication with the cavity. The device housing may include any suitable number of air inlets. The device housing may include a plurality of air inlets.

[0079] The aerosol generating device may comprise a user interface to activate the device, for example a button to initiate heating of the aerosol-forming substrate.

[0080] An aerosol-generating device may comprise a display to indicate the status of the device or the aerosol-forming substrate.

[0081] The aerosol generating device may comprise a puff sensor for sensing a puff taken by a user on the aerosol generating system.

[0082] Preferably, the aerosol generating device is portable. The aerosol generating device may be of a size comparable to a conventional cigar or cigarette. The aerosol generating device may have an overall length of between about 30 mm and about 150 mm. The aerosol generating device may have an outer diameter of between about 5 mm and about 30 mm.

[0083] According to a seventh aspect of the present disclosure, a method for manufacturing a retainer assembly for a cartridge of an aerosol generating system is provided. The retainer assembly may be a retainer assembly according to the first aspect or the second aspect of the present disclosure. The method may include providing a susceptor assembly. The susceptor assembly may include a wicking element having a planar shape and including a first side portion, a second side portion, and a central portion extending between the first side portion and the second side portion. The susceptor assembly may also include a susceptor element extending around at least a portion of the central portion of the wicking element. The method may include providing a retainer defining an airflow channel. The retainer may include a first slot and a second slot opposite to the first slot. The method may include inserting a first side portion of the wicking element into the first slot and inserting a second side portion of the wicking element into the second slot so that the central portion of the wicking element and the susceptor element are positioned within the airflow channel.

[0084] According to an eighth aspect of the present disclosure, a method for manufacturing a retainer assembly for a cartridge of an aerosol generating system is provided. The retainer assembly may be a retainer assembly according to any example or embodiment described herein according to the second aspect of the present disclosure. The method includes providing a susceptor assembly. The susceptor assembly includes a wicking element having a planar shape and including a first side portion, a second side portion, and a center portion extending between the first side portion and the second side portion. The susceptor assembly also includes a susceptor element extending around at least a portion of the center portion of the wicking element. The method also includes providing a retainer defining an airflow channel. The retainer includes a first slot and a second slot opposite to the first slot. The method also includes inserting a first side portion of the wicking element into the first slot and inserting a second side portion of the wicking element into the second slot so that the center portion of the wicking element and the susceptor element are positioned within the airflow channel.

[0085] The first slot may have at least one of a different size and a different shape than the second slot. The step of inserting the first side portion of the wicking element into the first slot and the second side portion of the wicking element into the second slot may include: pushing the first side portion of the wicking element through the second slot and into the airflow channel; pushing the central portion and the susceptor element of the wicking element through the second slot and into the airflow channel; and pushing the second side portion of the wicking element into the second slot and pushing the first side portion of the wicking element into the first slot.

[0086] The retainer may include a first retainer portion that partially defines each of the first slot and the second slot, and a second retainer portion that partially defines each of the first slot and the second slot. The step of inserting the first side portion of the wicking element into the first slot and the second side portion of the wicking element into the second slot may include: inserting the susceptor assembly into the first retainer portion or the second retainer portion; and connecting the second retainer portion to the first retainer portion so that the first retainer portion and the second retainer portion together define the first slot and the second slot, and so that the first side portion of the wicking element is received in the first slot and the second side portion of the wicking element is received in the second slot.

[0087] The retainer may have a tubular shape including a first end and a second end. Each of the first slot and the second slot may extend from the first end of the retainer so that each of the first slot and the second slot is open at the first end of the retainer. The step of inserting the first side portion of the wicking element into the first slot and the second side portion of the wicking element into the second slot may include sliding the first side portion of the wicking element into the first slot through the open end of the first slot and simultaneously sliding the second side portion of the wicking element into the second slot through the open end of the second slot.

[0088] 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.

[0089] Example Ex1: A holder assembly for a cartridge of an aerosol generating system, the holder assembly comprising:

[0090] A sensor assembly, the sensor assembly comprising:

[0091] a wicking element having a planar shape and comprising a first side portion, a second side portion, and a central portion extending between the first side portion and the second side portion; and

[0092] a susceptor element extending around at least a portion of the central portion of the wicking element; and

[0093] A retainer defining an airflow channel, wherein the retainer includes a first slot and a second slot opposite the first slot, wherein the first side portion of the wicking element is received in the first slot and the second side portion of the wicking element is received in the second slot so that a center portion of the wicking element and the susceptor element are positioned in the airflow channel.

[0094] Example Ex2: A retainer assembly according to Example Ex1, wherein only the first side portion of the wicking element is received in the first narrow groove and only the second side portion of the wicking element is received in the second narrow groove.

[0095] Example Ex3: A retainer assembly according to Example Ex1 or Ex2, wherein the retainer includes a tubular portion that at least partially defines the airflow channel, and wherein the first slot and the second slot are defined by the tubular portion.

[0096] Example Ex4: A retainer assembly according to Example Ex1, Ex2 or Ex3, wherein the first slot and the second slot are positioned on opposite sides of the airflow channel.

[0097] Example Ex5: A retainer assembly according to any of the preceding examples, wherein the airflow channel defines a longitudinal direction extending between a first end of the airflow channel and a second end of the airflow channel, and wherein the planar shape of the wicking element extends parallel to the longitudinal direction.

[0098] Example Ex6: A retainer assembly according to any of the preceding examples, wherein the airflow channel is defined in a longitudinal direction extending between a first end of the airflow channel and a second end of the airflow channel, wherein each of the first slot and the second slot has an elongated shape extending in the longitudinal direction.

[0099] Example Ex7: A retainer assembly according to any of the preceding examples, wherein the first slot has at least one of a different size and a different shape than the second slot.

[0100] Example Ex8: A retainer assembly according to Example Ex7, wherein each of the first slot and the second slot has a length and a width extending perpendicular to the length, and wherein at least one of the length of the second slot and the width of the second slot is respectively greater than the length of the first slot and the width of the first slot.

[0101] Example Ex9: A retainer assembly according to Example Ex8, wherein the airflow channel is defined in a longitudinal direction extending between a first end of the airflow channel and a second end of the airflow channel, and wherein the length of each of the first slot and the second slot extends in the longitudinal direction.

[0102] Example Ex10: A retainer assembly according to Example Ex7, Ex8 or Ex9, wherein the first slot has a rectangular or rounded rectangular shape.

[0103] Example Ex11: A retainer assembly according to Example Ex10, wherein the second slot has a rectangular or rounded rectangular shape.

[0104] Example Ex12: A retainer assembly according to Example Ex10, wherein the second slot includes an elongated portion and an enlarged portion at one end of the elongated portion.

[0105] Example Ex13: A retainer assembly according to Example Ex12, wherein the elongated portion of the second slot has a rectangular or rounded rectangular shape.

[0106] Example Ex14: A retainer assembly according to Example Ex12 or Ex13, wherein the enlarged portion has a circular shape.

[0107] Example Ex15: A retainer assembly according to Example Ex12, Ex13 or Ex14, wherein the airflow channel is defined in a longitudinal direction extending between a first end of the airflow channel and a second end of the airflow channel, wherein during use of the retainer assembly in a cartridge having an aerosol generating system, air flows through the airflow channel from the first end to the second end, and wherein the enlarged portion of the second slot is positioned closer to the second end of the airflow channel than the elongated portion of the second slot.

[0108] Example Ex16: A retainer assembly according to any one of Examples Ex1 to Ex6, wherein the retainer includes a first retainer portion and a second retainer portion connected to the first retainer portion, wherein each of the first slot and the second slot is partially defined by the first retainer portion and partially defined by the second retainer portion.

[0109] Example Ex17: A retainer assembly according to Example Ex16, wherein each of the first retainer portion and the second retainer portion has a tubular shape.

[0110] Example Ex18: A retainer assembly according to Example Ex17, wherein each of the first retainer portion and the second retainer portion includes an upstream end and a downstream end, and wherein the upstream end of the second retainer portion is connected to the downstream end of the first retainer portion.

[0111] Example Ex19: A retainer assembly according to Example Ex16, wherein the airflow channel is defined in a longitudinal direction extending between a first end of the airflow channel and a second end of the airflow channel, and wherein each of the first retainer portion and the second retainer portion extends between the first end and the second end.

[0112] Example Ex20: A retainer assembly according to Example Ex16 or Ex19, wherein each of the first retainer portion and the second retainer portion has a semi-tubular shape.

[0113] Example Ex21: A retainer assembly according to any one of Examples Ex16 to Ex20, wherein the second retainer portion is connected to the first retainer portion by an interference fit.

[0114] Example Ex22: A retainer assembly according to any one of Examples Ex16 to Ex21, wherein the retainer further comprises a retaining portion, wherein the retaining portion is arranged to fix the second retainer portion to the first retainer portion.

[0115] Example Ex23: A retainer assembly according to Example Ex22, wherein the retaining portion is engaged with at least one of the first retainer portion and the second retainer portion by an interference fit.

[0116] Example Ex24: A retainer assembly according to Example Ex22 or Ex23, wherein the retaining portion is integrally formed with the first retainer portion or the second retainer portion.

[0117] Example Ex25: A retainer assembly according to Example Ex22 or Ex23, wherein the retaining portion has an annular shape and extends around a portion of the first retainer portion and a portion of the second retainer portion.

[0118] Example Ex26: A retainer assembly according to any one of Examples Ex1 to Ex6, wherein the retainer has a tubular shape, the tubular shape includes a first end and a second end, and wherein each of the first slot and the second slot extends from the first end of the retainer so that each of the first slot and the second slot is open at the first end of the retainer.

[0119] Example Ex27: A retainer assembly according to Example Ex26, wherein each of the first slot and the second slot includes an insertion portion extending from the first end of the retainer and a retaining portion extending from the insertion portion.

[0120] Example Ex28: A retainer assembly according to Example Ex27, wherein each insertion portion has a conical shape.

[0121] Example Ex29: A retainer assembly according to Example Ex27 or Ex28, wherein each insert portion has a cross-sectional dimension that decreases in a direction along the retainer from the first end.

[0122] Example Ex30: A retainer assembly according to Example Ex27, Ex28 or Ex29, wherein each retaining portion has a constant cross-sectional size in a direction along the retainer from the first end.

[0123] Example Ex31: A retainer assembly according to any one of Examples Ex27 to Ex30, wherein the first side portion of the wicking element and the second side portion of the wicking element are respectively received only within the retaining portions of the first slot and the second slot.

[0124] Example Ex32: The retainer assembly according to any one of Examples Ex26 to Ex30 further includes a cover connected to the first end of the retainer, wherein the cover is arranged to close each of the first slot and the second slot at the first end of the retainer.

[0125] Example Ex33: A retainer assembly according to any of the preceding examples, wherein the first side portion of the wicking element is received in the first narrow groove by an interference fit, and wherein the second side portion of the wicking element is received in the second narrow groove by an interference fit.

[0126] Example Ex34: A retainer assembly according to any of the preceding examples, wherein the sensor assembly has a planar shape, the planar shape comprising a first planar surface and a second planar surface opposite to the first planar surface.

[0127] Example Ex35: A retainer assembly according to Example Ex34, wherein the sensor assembly has a thickness extending between the first planar surface and the second planar surface, and wherein the thickness of the sensor assembly is greater at the center portion of the wicking element than each of the first side portion of the wicking element and the second side portion of the wicking element.

[0128] Example Ex36: A retainer assembly according to Example Ex34 or Ex35, wherein the sensor assembly has an upstream end and a downstream end, and the upstream end and the downstream end are arranged so that air flows through the sensor assembly from the upstream end to the downstream end during use of the retainer assembly in a cartridge having an aerosol generating system, wherein the sensor assembly has a thickness extending between the first planar surface and the second planar surface, and wherein the thickness of the sensor assembly at the central portion of the wicking element is greater at the downstream end than at the upstream end.

[0129] Example Ex37: A retainer assembly according to any of the preceding examples, wherein the sensor element comprises at least one sensor material strip having an annular shape and extending around the central portion of the wicking element.

[0130] Example Ex38: A cartridge for an aerosol generating system, the cartridge comprising:

[0131] A retainer assembly according to any preceding example; and

[0132] A reservoir for a liquid aerosol-forming substrate, wherein the reservoir is in fluid communication with the first side portion of the wicking element and the second side portion of the wicking element through the first slot and the second slot, respectively.

[0133] Example Ex39: A barrel according to Example Ex38, wherein the reservoir extends around at least a portion of the outer surface of the retainer.

[0134] Example Ex40: A cartridge according to Example Ex38 or Ex39, wherein the reservoir has an annular shape.

[0135] Example Ex41: The cartridge according to Example Ex38, Ex39 or Ex40 further comprises a mouthpiece defining an air outlet, wherein the air outlet is fluidically connected to a downstream end of the airflow channel.

[0136] Example Ex42: An aerosol generating system, comprising:

[0137] A cartridge according to any one of Examples Ex38 to Ex41; and

[0138] An aerosol generating device, the aerosol generating device comprising:

[0139] a device housing defining a cavity for receiving at least a portion of the retainer assembly such that the susceptor assembly is positioned within the cavity; and

[0140] An inductor coil is arranged to generate a varying magnetic field within the cavity.

[0141] Example Ex43: A method of manufacturing a holder assembly for a cartridge of an aerosol generating system, the method comprising:

[0142] A susceptor assembly is provided, the susceptor assembly comprising:

[0143] a wicking element having a planar shape and comprising a first side portion, a second side portion, and a central portion extending between the first side portion and the second side portion; and

[0144] a susceptor element extending around at least a portion of the central portion of the wicking element;

[0145] providing a retainer defining an airflow channel, wherein the retainer includes a first slot and a second slot opposite the first slot; and

[0146] The first side portion of the wicking element is inserted into the first slot and the second side portion of the wicking element is inserted into the second slot such that the central portion of the wicking element and the susceptor element are positioned within the airflow channel.

[0147] Example Ex44: A method according to example Ex43, wherein the first slot has at least one of a different size and a different shape than the second slot, and wherein the steps of inserting the first side portion of the wicking element into the first slot and inserting the second side portion of the wicking element into the second slot include:

[0148] pushing the first side portion of the wicking element through the second slot and into the airflow channel;

[0149] pushing the central portion of the wicking element and the susceptor element through the second slot and into the airflow channel; and

[0150] The second side portion of the wicking element is pushed into the second slot and the first side portion of the wicking element is pushed into the first slot.

[0151] Example Ex45: A method according to example Ex43, wherein the retainer includes a first retainer portion that partially defines each of the first slot and the second slot, wherein the retainer also includes a second retainer portion that partially defines each of the first slot and the second slot, and wherein the steps of inserting the first side portion of the wicking element into the first slot and inserting the second side portion of the wicking element into the second slot include:

[0152] inserting the susceptor assembly into the first holder portion or the second holder portion; and

[0153] The second retainer portion is connected to the first retainer portion so that the first retainer portion and the second retainer portion together define the first slot and the second slot, and so that the first side portion of the wicking element is received in the first slot and the second side portion of the wicking element is received in the second slot.

[0154] Example Ex46: A method according to example Ex43, wherein the retainer has a tubular shape including a first end and a second end, wherein each of the first slot and the second slot extends from the first end of the retainer so that each of the first slot and the second slot is open at the first end of the retainer, and wherein the steps of inserting the first side portion of the wicking element into the first slot and inserting the second side portion of the wicking element into the second slot include:

[0155] The first side portion of the wicking element is slid into the first slot through the open end of the first slot, and the second side portion of the wicking element is simultaneously slid into the second slot through the open end of the second slot.

[0156] Several examples will now be further described with reference to the accompanying drawings, in which:

[0157] Figure 1 shows a longitudinal cross-sectional view of a cartridge according to an embodiment of the present disclosure, the cartridge including a retainer;

[0158] Figure 2 Shown rotated 90 degrees Figure 1 Another longitudinal cross-sectional view of the tube;

[0159] Figure 3 Show Figure 1 and 2 A side cross-sectional view of a cylinder;

[0160] Figure 4 Show Figures 1 to 3 A perspective view of a sensor assembly of a cartridge;

[0161] Figure 5 shows a first side view of a cartridge holder according to an embodiment of the present disclosure;

[0162] Figure 6 Show Figure 5 A second side view of the retainer;

[0163] Figure 7 shows a side view of an alternative retainer assembly according to an embodiment of the present disclosure, wherein the retainer assembly is in a partially assembled state;

[0164] Figure 8 Shown in fully assembled state Figure 7 A side view of a retainer assembly;

[0165] Fig. 9 An exploded perspective view showing another alternative retainer assembly according to an embodiment of the present disclosure;

[0166] Fig.10 Shown in assembled state Fig. 9 A retainer assembly;

[0167] Fig.11 A perspective view showing another alternative retainer assembly according to an embodiment of the present disclosure;

[0168] Fig.12 shows a side view of another alternative retainer assembly according to an embodiment of the present disclosure;

[0169] Fig.13 Shown including Figures 1 to 3 a longitudinal cross-sectional view of an aerosol generating system of a cartridge and an aerosol generating device, wherein the cartridge is separated from the aerosol generating device; and

[0170] Fig.14 Show Fig.13 A longitudinal cross-sectional view of an aerosol generating system of claim 1, wherein the cartridge is coupled to an aerosol generating device.

[0171] Figure 1 and 2 Two longitudinal cross-sectional views of a cartridge 10 for an aerosol generating system, a cartridge 10 according to an embodiment of the present disclosure, are shown. The two cross-sectional views are taken in two planes perpendicular to each other. Figure 3 A side cross-sectional view of the cartridge 10 is shown. Figure 1 The cross-sectional view of Figure 3 The line 1-1 in the figure indicates. Figure 2 The cross-sectional view of Figure 3 Indicated by line 2-2.

[0172] The cartridge 10 includes a holder 14 and a susceptor assembly 12 mounted in the holder 14. The susceptor assembly 12 and the holder 14 together form a holder assembly 15. The susceptor assembly 12 is planar and thin, having a thickness dimension that is substantially smaller than the length dimension and the width dimension. The susceptor assembly 12 is shaped as a rectangle and includes a susceptor element 16 wrapped around a wicking element 18. The width 19 of the susceptor element 16 is less than the width 21 of the wicking element 18, wherein the susceptor element 16 is wrapped around a central portion 31 of the wicking element 18 to define an externally exposed portion of the wicking element 18 that is not surrounded by the susceptor element 16. The externally exposed portion of the wicking element 18 includes a first side portion 33 and a second side portion 35. The first side portion 33 and the second side portion 35 protrude into one of the two channels 45 through a first slot 28 and a second slot 29, respectively. The first slot 28 and the second slot 29 are arranged on opposite sides of the inner side wall 27 of the holder 14. The interior sidewall 27 defines an airflow passage 26 in which the susceptor assembly 12 is positioned.

[0173] The susceptor element 16 comprises a sintered mesh formed of ferritic stainless steel wire and austenitic stainless steel wire. The wicking element 18 comprises a porous body of rayon. The wicking element 18 is configured to deliver the liquid aerosol-forming substrate to the central portion 31 and the susceptor element 16 wrapped around the central portion 31 via the first side portion 33 and the second side portion 35.

[0174] The susceptor element 16 is configured to be heated by the penetration of a changing magnetic field for vaporizing the aerosol-forming substrate. The first side portion 33 and the second side portion 35 of the wicking element 18 protrude through the first slot 28 and the second slot 29 in the holder 14, respectively, so that the holder 14 supports the susceptor assembly 12 in place in the airflow channel 26.

[0175] The susceptor assembly 12 is partially disposed inside the airflow channel 26 of the tubular holder 14 and extends in a plane parallel to the central longitudinal axis of the holder 14. The susceptor element 16 is completely disposed within the airflow channel 26 of the holder 14, and the externally exposed portion 20 of the wicking element 18 extends through a pair of openings 28 in the interior sidewall 27 of the holder 14 into the two channels 45. The first side portion 33 and the second side portion 35 of the wicking element 18 define a mounting area of ​​the susceptor assembly 12 for mounting the susceptor assembly 12 in the holder 14. The first side portion 33 and the second side portion 35 of the wicking element 18 are received and retained in the first slot 28 and the second slot 29 by an interference fit. Advantageously, the interference fit can simplify the manufacture of the holder assembly 15. Advantageously, the interference fit can reduce or prevent leakage of the liquid aerosol-forming substrate from the channel 45 into the airflow channel 26.

[0176] Tube 10 has outer shell 36, and described outer shell has mouth end and the connection end relative to mouth end.The mouth end of outer shell 36 defines the mouthpiece 41 with air outlet 38 at the mouth end of tube 10.During use, aerosol is delivered to user for inhalation by air outlet 38.As described in detail below, the connection end of outer shell 36 is configured to be used for tube 10 being connected to aerosol generating device.Outer shell 36 limits inner space, and retainer assembly 15 is contained in described inner space.Retainer assembly 15 is received in the inner space of outer shell 36 by interference fit.Retainer assembly 15 is positioned in outer shell 36, so that receptor assembly 12 and retainer 14 are positioned towards the connection end of tube 10.Outer shell 36 is formed by the moldable plastic material such as polypropylene.

[0177] The outer width of the outer housing 36 is greater at the mouth end of the barrel 10 than at the connection end to define a mouthpiece 41. The change in the outer width of the outer housing 36 is a step change that forms a shoulder 37. The shoulder 37 enables the connection end of the barrel 10 to be received in the cavity of the aerosol generating device, wherein the shoulder 37 locates the barrel in the correct position in the device. The shoulder 37 also enables the mouthpiece 41 to be retained outside the aerosol generating device, wherein the mouth end of the barrel 10 conforms to the external shape of the aerosol generating device.

[0178] The cartridge 10 further comprises a liquid reservoir 44. The liquid reservoir 44 is defined in the cartridge 10 for holding the liquid aerosol-forming substrate 42.

[0179] The liquid reservoir 44 is positioned within the mouthpiece 41 and comprises an annular space defined by the outer housing 36 .

[0180] The inner side wall of the mouthpiece 41 defines a further airflow passage 48 extending between the downstream end of the airflow passage 26 of the holder 14 and the air outlet 38 of the mouthpiece 41 .

[0181] The liquid reservoir 44 also includes two channels 45 defined between the outer housing 36 at the connection end and the holder 14. The two channels 45 extend from the annular space defined by the mouthpiece 41 to the connection end of the cartridge 10. The first and second side portions 33, 35 of the wicking element 18 extend through the first and second slots 28, 29 in the inner side wall 27 of the holder 14 into the two channels 45 on opposite sides of the holder 14.

[0182] The cartridge 10 further comprises a cover 30 partially closing the upstream end of the air flow passage 26. The cover 30 comprises a plurality of air inlets 32 which enable air to be drawn into the air flow passage 26 through the partially closed end.

[0183] Figure 4A perspective view of the susceptor assembly 12 is shown. Figure 4 Arrows 163 are included which represent airflow passing over the susceptor element 16 from the upstream end of the susceptor assembly 12 to the downstream end of the susceptor assembly 12 . Figure 4 Also included are arrows 165 which represent the flow of liquid aerosol-forming substrate into the first side portion 33 and the second side portion 35 of the wicking element 18 .

[0184] The susceptor element 16 is defined by a single strip of susceptor material wrapped around a central portion 31 of the wicking element 18. The wicking element 18 has a uniform thickness. The strip of susceptor material covers the opposing upper and lower planar surfaces of the wicking element 18, as well as the opposing upstream and downstream faces of the wicking element 18. The first and second ends of the strip of susceptor material extend toward each other from opposite directions along the downstream end face of the wicking element 18 to form a seam 161 in the susceptor element 16. Due to the seam 161, the thickness of the central portion 31 of the susceptor assembly 12, including the wicking element 18 and the central portion of the susceptor element 16, is greater at the downstream end of the wicking element 18.

[0185] Figure 5 and 6 Shown are first and second side views of the retainer 14. The first slot 28 has a shape that is substantially the same as the cross-sectional shape of the first side portion 33 of the wicking element 18. The first slot 28 is sized to receive the first side portion 33 of the wicking element 18 with an interference fit.

[0186] To facilitate insertion of the susceptor assembly 12 into the holder 14 during manufacture of the holder assembly 15, the second slot 29 has a slightly different size and shape than the first slot 28. The second slot 29 includes an elongated portion 290 having a similar shape as the first slot 28. The height of the elongated portion 290 of the second slot 29 is slightly greater than the height of the first slot 28 to accommodate the combined thickness of the central portion 31 of the wicking element 18 and the susceptor element 16. The second slot 29 also includes an enlarged portion 292 at the downstream end of the elongated portion 290. The enlarged portion 292 accommodates the additional thickness of the susceptor assembly 12 created by the seam 161 of the susceptor element 16.

[0187] During manufacture of the retainer assembly 15, the first side portion 33 of the wicking element 18 is pushed through the second slot 29 and into the airflow channel 26. Next, the central portion 31 of the wicking element 18 and the susceptor element 16 are pushed through the second slot 29 and into the airflow channel 29. Finally, the second side portion 35 of the wicking element 18 is pushed into the second slot 29 and simultaneously the first side portion 33 of the wicking element 18 is pushed into the first slot 28.

[0188] Figure 7 and 8 Show that it can be Figures 1 to 3 A first side view and a second side view of an alternative retainer assembly 1015 for use with the cartridge 10. The retainer assembly 1015 is Figure 7 is shown in a partially assembled state and in Figure 8 is shown in a fully assembled state.

[0189] The holder assembly 1015 includes a holder 1014 and a susceptor assembly 12. The susceptor assembly 12 and Figures 1 to 6 The sensor assembly 12 is the same.

[0190] The retainer 1014 includes a first retainer portion 1017 and a second retainer portion 1019. Each of the first retainer portion 1017 and the second retainer portion 1019 includes a pair of open-ended slots that form a portion of the first slot 28 and the second slot 29 when the retainer assembly 15 is fully assembled. During manufacturing, portions of the first side portion 33 and the second side portion 35 of the wicking element 18 are inserted into the open-ended slots of the first retainer portion 1017, as shown in FIG. Figure 7 Next, the second retainer portion 1019 is pushed onto the first retainer portion 1017 so that the first side portion 33 and the remainder of the second side portion 35 of the wicking element 18 are received in the open-ended narrow slot of the second retainer portion 1019, as shown in FIG. Figure 8 A portion of the first retainer portion 1017 is received within the second retainer portion 1019 by an interference fit to connect the second retainer portion 1019 to the first retainer portion 1017 .

[0191] Fig. 9 and 10 Show that it can be Figures 1 to 3 Two views of another alternative retainer assembly 2015 for use with the cartridge 10. The retainer assembly 2015 is Fig. 9 is shown in an exploded state and in Fig.10 is shown in a fully assembled state.

[0192] The holder assembly 2015 includes a holder 2014 and a susceptor assembly 12. The susceptor assembly 12 and Figures 1 to 6 The sensor assembly 12 is the same.

[0193] The retainer 2014 includes a first retainer portion 2017 and a second retainer portion 2019. Each of the first retainer portion 2017 and the second retainer portion 2019 has a semi-tubular shape and defines a longitudinal half of each of the first slot 28 and the second slot 29. During manufacturing, the first side portion 33 and the second side portion 35 of the wicking element 18 are positioned between the first retainer portion 2017 and the second retainer portion 2019. Then, the first retainer portion 2017 and the second retainer portion 2019 contact each other to form the first slot 28 and the second slot 29, wherein the first side portion 33 and the second side portion 35 of the wicking element 18 are positioned within the first slot 28 and the second slot 29. Then, a retaining portion 2021 in the form of an annular ring is pushed onto the ends of the combined first retainer portion 2017 and the second retainer portion 2019 to secure the first retainer portion 2017 and the second retainer portion 2019 to each other.

[0194] Fig.11 Show that it can be Figures 1 to 3 A perspective view of another alternative retainer assembly 3015 for use with the cartridge 10 of FIG. The retainer assembly 3015 includes a retainer 3014 and a susceptor assembly 12. The susceptor assembly 12 is Figures 1 to 6 The sensor assembly 12 is the same.

[0195] The retainer 3014 has a tubular shape, wherein the first slot 28 and the second slot 29 are open-ended slots extending from the upstream end 3023 of the retainer 3014. During manufacturing, the first side portion 33 and the second side portion 35 of the wicking element 18 are inserted into the first slot 28 and the second slot 29 through the open ends of the first slot 28 and the second slot 29. The first side portion 33 and the second side portion 35 of the wicking element 18 are retained in the first slot 28 and the second slot 29. The open ends of the first slot 28 and the second slot 29 can be removed by the susceptor assembly as described above. Figure 1 and 2 The cover 30 is described as closed.

[0196] Fig.12 Show that it can be Figures 1 to 3 A side view of another alternative retainer assembly 4015 for use with the cartridge 10 of FIG. The retainer assembly 4015 includes a retainer 4014 and a susceptor assembly 12. The susceptor assembly 12 is Figures 1 to 6 The same as the sensor assembly 12. The retainer 4014 is Fig.11The present invention is a variation of the retainer 3014 of the embodiment of the present invention and differs in the shape of the open ends of the first slot 28 and the second slot 29. Specifically, the first slot 28 and the second slot 29 each include a tapered insertion portion 4028 to facilitate the insertion of the first side portion 33 and the second side portion 35 of the wicking element 18 into the first slot 28 and the second slot 29.

[0197] Fig.13 A schematic diagram showing a cross section of an aerosol generating system 100 according to the present disclosure is shown, with the cartridge 10 separated from the aerosol generating device 60 .

[0198] Tube 10 and Figure 1 , 2 The same as the cartridge presented in 3 and its corresponding description.

[0199] The aerosol generating device 60 comprises a generally cylindrical device housing 62 having a connection end and a distal end opposite the connection end. A cavity 64 for receiving the connection end of the cartridge 10 is located at the connection end of the device 60, and an air inlet 65 is provided through the device housing 62 at the base of the cavity 64 to enable ambient air to be drawn into the cavity 64.

[0200] The device 60 also includes an induction heating arrangement disposed within the device outer housing 62. The induction heating arrangement includes an inductor coil 90, a controller 70, and a power source 72. The power source 72 includes a rechargeable nickel-cadmium battery that can be recharged via an electrical connector (not shown) at the distal end of the device 60. The controller 70 is connected to the power source 72 and to the inductor coil 90 so that the controller 70 controls the supply of power to the inductor coil 90. The controller 70 is configured to supply an alternating current to the inductor coil 90.

[0201] When the cartridge 10 is received in the cavity 64, a single inductor coil 90 is positioned around the susceptor assembly 12. The inductor coil 90 is made of copper wire having a circular cross-section and is arranged on a coil former element (not shown). The inductor coil 90 is a helical coil and defines a circular cross-section when viewed along the longitudinal axis of the aerosol generating device 60.

[0202] The inductor coil 90 is configured such that when an alternating current is supplied to the inductor coil 90 , the inductor coil 90 generates an alternating magnetic field in the area of ​​the susceptor assembly 12 when the cartridge 10 is received in the cavity 64 .

[0203] The induction heating arrangement further comprises a flux concentrator element 91. The flux concentrator element 91 has a larger radius than the inductor coil 90 and thus partially surrounds the inductor coil 90. The flux concentrator element 91 is configured to reduce stray power losses from the generated magnetic field.

[0204] Fig.14 Show Fig.13 Schematic diagram of a cross-section of an aerosol generating system 100 , but with the cartridge 10 coupled to an aerosol generating device 60 .

[0205] In operation, when a user draws on the mouthpiece 41 of the cartridge 10, ambient air is drawn into the base of the cavity 64 through the air inlet 65, and into the cartridge 10 through the air inlet 32 ​​in the cap 30 of the cartridge 10. Ambient air flows through the cartridge 10 from the cap 30, through the airflow channel 26, past the susceptor assembly 12, and through the air outlet 38.

[0206] When the system is enabled, the controller 70 controls the supply of electrical power from the power source 72 to the inductor coil 90 .

[0207] The controller 72 is coupled to the airflow sensor 63. The airflow sensor 63 is in fluid communication with the passage of ambient air drawn through the system by the user. The controller 72 supplies electrical power to the inductor coil 90 when the airflow sensor 63 detects that the user is drawing on the cartridge 10.

[0208] When the system 100 is activated, an alternating current is generated in the inductor coil 90, which generates an alternating magnetic field in the cavity 64 (where the susceptor assembly 12 is located), thereby heating the susceptor element 16. The liquid aerosol-forming substrate in the channel 45 is drawn into the susceptor assembly 12 through the wicking element 18 toward the susceptor element 16. The liquid aerosol-forming substrate 42 at the susceptor element 16 is heated, and volatile compounds from the heated aerosol-forming substrate are released into the airflow channel 26 of the cartridge 10 and cool to form an aerosol. The aerosol is entrained in the air drawn through the airflow channel 26 of the cartridge 10 and is drawn out of the cartridge 10 at the air outlet 38 for inhalation by the user.

Claims

1. A holder assembly for a cartridge of an aerosol generating system, the holder assembly comprising: A sensor assembly, the sensor assembly comprising: a wicking element having a planar shape and comprising a first side portion, a second side portion, and a central portion extending between the first side portion and the second side portion; and a susceptor element extending around at least a portion of the central portion of the wicking element; and A retainer defining an airflow channel, wherein the retainer includes a first slot and a second slot opposite the first slot, wherein the first side portion of the wicking element is received in the first slot and the second side portion of the wicking element is received in the second slot so that a center portion of the wicking element and the susceptor element are positioned in the airflow channel.

2. The retainer assembly according to claim 1, wherein: The first slot has at least one of a different size and a different shape than the second slot.

3. The retainer assembly according to claim 1, wherein: The retainer includes a first retainer portion and a second retainer portion connected to the first retainer portion, wherein each of the first slot and the second slot is partially defined by the first retainer portion and partially defined by the second retainer portion.

4. The retainer assembly according to claim 3, wherein: Each of the first retainer portion and the second retainer portion includes an upstream end and a downstream end, and wherein the upstream end of the second retainer portion is connected to the downstream end of the first retainer portion.

5. The retainer assembly according to claim 3, wherein: The airflow channel defines a longitudinal direction extending between a first end of the airflow channel and a second end of the airflow channel, and wherein each of the first retainer portion and the second retainer portion extends between the first end and the second end.

6. The holder assembly according to claim 3 or 5, wherein: Each of the first retainer portion and the second retainer portion has a semi-tubular shape.

7. The retainer assembly according to claim 1, wherein: The retainer has a tubular shape including a first end and a second end, and wherein each of the first slot and the second slot extends from the first end of the retainer such that each of the first slot and the second slot is open at the first end of the retainer.

8. The retainer assembly according to claim 7, wherein: Each of the first slot and the second slot includes an insertion portion extending from the first end of the retainer and a retaining portion extending from the insertion portion.

9. The retainer assembly according to claim 8, wherein: Each insertion portion has a tapered shape.

10. A cartridge for an aerosol generating system, the cartridge comprising: A retainer assembly according to any preceding claim; as well as A reservoir for a liquid aerosol-forming substrate, wherein the reservoir is in fluid communication with the first side portion of the wicking element and the second side portion of the wicking element through the first slot and the second slot, respectively.

11. An aerosol generating system comprising: The cartridge according to claim 10; as well as An aerosol generating device, the aerosol generating device comprising: a device housing defining a cavity for receiving at least a portion of the retainer assembly such that the susceptor assembly is positioned within the cavity; as well as An inductor coil is arranged to generate a varying magnetic field within the cavity.

12. A method of manufacturing a holder assembly for a cartridge of an aerosol generating system, the method comprising: A susceptor assembly is provided, the susceptor assembly comprising: a wicking element having a planar shape and comprising a first side portion, a second side portion, and a central portion extending between the first side portion and the second side portion; and a susceptor element extending around at least a portion of the central portion of the wicking element; providing a retainer defining an airflow channel, wherein the retainer includes a first slot and a second slot opposite the first slot; and The first side portion of the wicking element is inserted into the first slot and the second side portion of the wicking element is inserted into the second slot such that the central portion of the wicking element and the susceptor element are positioned within the airflow channel.

13. The method according to claim 12, wherein: The first slot has at least one of a different size and a different shape than the second slot, and wherein the steps of inserting the first side portion of the wicking element into the first slot and inserting the second side portion of the wicking element into the second slot include: pushing the first side portion of the wicking element through the second slot and into the airflow channel; pushing the central portion of the wicking element and the susceptor element through the second slot and into the airflow channel; and The second side portion of the wicking element is pushed into the second slot and the first side portion of the wicking element is pushed into the first slot.

14. The method according to claim 12, wherein: The retainer includes a first retainer portion that partially defines each of the first slot and the second slot, wherein the retainer also includes a second retainer portion that partially defines each of the first slot and the second slot, and wherein the steps of inserting the first side portion of the wicking element into the first slot and inserting the second side portion of the wicking element into the second slot include: inserting the susceptor assembly into the first holder portion or the second holder portion; and The second retainer portion is connected to the first retainer portion so that the first retainer portion and the second retainer portion together define the first slot and the second slot, and so that the first side portion of the wicking element is received in the first slot and the second side portion of the wicking element is received in the second slot.

15. The method according to claim 12, wherein: The holder has a tubular shape including a first end and a second end, wherein each of the first slot and the second slot extends from the first end of the holder such that each of the first slot and the second slot is open at the first end of the holder, and wherein the steps of inserting the first side portion of the wicking element into the first slot and inserting the second side portion of the wicking element into the second slot include: The first side portion of the wicking element is slid into the first slot through the open end of the first slot, and the second side portion of the wicking element is simultaneously slid into the second slot through the open end of the second slot.

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