Aerosol provision system, heater assembly and method

Abstract

An aerosol provision system (1) is described, comprising a heater assembly (6) and an aerosol generating material store. The heater assembly comprises a substrate (62), a heater layer (64) disposed on at least a first surface (62a) of the substrate and configured to generate heat, a first set of one or more capillaries (66, 66a) extending from a second surface (62b) of the substrate through the substrate and the heater layer and having a first property, and a second set of one or more capillaries (66, 66b) extending from the second surface of the substrate through the substrate and the heater layer and having a second property different from the first property. The aerosol generating material store is in fluid communication with the second surface of the substrate and comprises a first aerosol generating material and a second aerosol generating material. The second aerosol generating material has a higher viscosity than the first aerosol generating material, and the first set of one or more capillaries is configured to impede flow of the second aerosol generating material. Also described are a consumable for use with the aerosol provision system, a method of manufacturing the aerosol provision system or the consumable, and an aerosol provision device.

Description

Technical Field

[0001] This disclosure relates to electronic aerosol supply systems, such as nicotine delivery systems (e.g., e-cigarettes). Background Technology

[0002] Electronic aerosol supply systems, such as those for electronic cigarettes (e-cigarettes), typically include a reservoir of a source liquid containing a formulation from which an aerosol is generated, for example, by heating and evaporation. This formulation typically includes nicotine. Therefore, the aerosol source for the aerosol supply system may include a heater having a heating element arranged to receive the source liquid from the reservoir, for example, by wicking / capillary action. When a user inhales on the device, electricity is supplied to the heating element to evaporate the source liquid near the heating element, thereby generating an aerosol for the user to inhale. Such devices typically have one or more inlet ports located remotely from the mouthpiece end of the system. When a user inhales on a mouthpiece connected to the system, air is drawn in through these inlet ports and passes through the aerosol source. A flow path exists connecting the aerosol source and the opening in the mouthpiece, such that the inhaled air continues along the flow path past the aerosol source to the mouthpiece opening, thereby entraining some aerosol from the aerosol source. Air carrying aerosols exits the aerosol supply system through the mouthpiece opening for the user to inhale.

[0003] Typically, such electronic aerosol supply systems include heater assemblies adapted to heat the source liquid to form an aerosol. An example of such a heater assembly is a wick and coil heater assembly, which is formed by a coil (typically a nickel-chromium alloy NiCr8020) wound or coiled around a wick, which typically comprises bundled fibers, such as cotton fibers, extending along the longitudinal axis of the coil. The end of the wick extends to one side of the coil and is inserted into a reservoir of the source liquid. However, such heater assemblies are not necessarily suitable for all applications or configurations of electronic aerosol supply systems.

[0004] So-called microfluidic heater assemblies have been proposed in an attempt to address some of the problems associated with the aforementioned heater assemblies.

[0005] Additionally, there is a desire to provide users of aerosol supply systems with the ability to deliver different sensory experiences by combining aerosols formed from different aerosol-generating materials. Such solutions are typically more expensive, involving the provision of multiple heaters, each supplied by a separate liquid reservoir. However, in part due to the additional manufacturing costs potentially associated with the microfluidic heater assembly, such an approach may not be suitable for cartridge designs employing microfluidic heater assemblies.

[0006] Alternatively, in the fabrication of such microfluidic heater assemblies, the performance characteristics related to how the liquid (e.g., a slurry) interacts with the heater assembly may not be satisfactory, and thus designers of such microfluidic heater assemblies may be forced to make trade-offs between certain performance characteristics. This can result in microfluidic heater assemblies having generally less than ideal performance characteristics.

[0007] It describes different approaches to seeking help to solve some of these problems. Summary of the Invention

[0008] According to a first aspect of certain embodiments, an aerosol supply system is provided, comprising a heater assembly and an aerosol generating material storage region. The heater assembly includes: a substrate; a heater layer disposed on at least a first surface of the substrate and configured to generate heat; a first set of one or more capillaries extending from a second surface of the substrate through the substrate and the heater layer and having a first characteristic; and a second set of one or more capillaries extending from the second surface of the substrate through the substrate and the heater layer and having a second characteristic different from the first characteristic. The aerosol generating material storage region is in fluid communication with the second surface of the substrate and includes a first aerosol generating material and a second aerosol generating material. The second aerosol generating material has a higher viscosity than the first aerosol generating material, and the first set of one or more capillaries is configured to impede the flow of the second aerosol generating material.

[0009] According to some examples of the first aspect, a first group of one or more capillaries is configured to impede the flow of the second aerosol generating material along the first group of one or more capillaries.

[0010] According to some examples of the first aspect, the second set of one or more capillaries is configured to allow the first aerosol generating material and the second aerosol generating material to flow along the second set of one or more capillaries.

[0011] According to some examples of the first aspect, the aerosol generated by the first aerosol generating material when aerosolized by the heater layer has different characteristics compared to the aerosol generated by the second aerosol generating material when aerosolized by the heater layer.

[0012] According to some examples of the first aspect, a first set of one or more capillaries is disposed in one or more regions of the heater assembly such that it impedes or prevents the second aerosol generating material from being supplied to the heater layer located in one or more regions of the heater assembly.

[0013] According to some examples of the first aspect, the heater layer in one or more regions of the heater assembly is configured such that one or more regions have different operating characteristics compared to the rest of the heater layer during use.

[0014] According to some examples of the first aspect, the first group of one or more capillaries differs from the second group of one or more capillaries in that at least one of the following is true: the size of the cross-section, the shape of the cross-section, and the nature of the side surfaces of the one or more capillaries.

[0015] According to some examples of the first aspect, the aerosol generating material storage section includes a first aerosol generating material storage section for storing a first aerosol generating material and a second aerosol generating material storage section for storing a second aerosol generating material, wherein both the first aerosol generating material storage section and the second aerosol generating material storage section are configured to be in fluid communication with a second surface of the substrate of the heater assembly.

[0016] According to a second aspect of certain embodiments, a consumable is provided for use with an aerosol supply system to generate an aerosol. The consumable includes a heater assembly and an aerosol generating material storage region. The heater assembly includes: a substrate; a heater layer disposed on at least a first surface of the substrate and configured to generate heat; a first set of one or more capillaries extending from a second surface of the substrate through the substrate and the heater layer and having a first characteristic; and a second set of one or more capillaries extending from the second surface of the substrate through the substrate and the heater layer and having a second characteristic different from the first characteristic. The aerosol generating material storage region is in fluid communication with the second surface of the substrate and includes a first aerosol generating material and a second aerosol generating material. The second aerosol generating material has a higher viscosity than the first aerosol generating material, and the first set of one or more capillaries is configured to impede the flow of the second aerosol generating material.

[0017] According to a third aspect of certain embodiments, a method of manufacturing an aerosol supply system or a consumable for use with an aerosol supply system is provided. The aerosol supply system or consumable includes a heater assembly comprising a substrate and a heater layer disposed on at least a first surface of the substrate and configured to generate heat. The aerosol supply system or consumable also includes an aerosol generating material storage portion comprising a first aerosol generating material and a second aerosol generating material, wherein the second aerosol generating material has a higher viscosity than the first aerosol generating material. The method includes: providing a first set of one or more capillaries extending from a second surface of the substrate through the substrate and the heater layer and having a first characteristic; and providing a second set of one or more capillaries extending from the second surface of the substrate through the substrate and the heater layer and having a second characteristic different from the first characteristic. The first set of one or more capillaries is configured to impede the flow of the second aerosol generating material.

[0018] According to a fourth aspect of certain embodiments, an aerosol supply device is provided, comprising a heater device and an aerosol generating material storage device. The heater device includes: a substrate; a heater layer device disposed on at least a first surface of the substrate and configured to generate heat; a first set of capillary devices extending from a second surface of the substrate through the substrate and the heater layer device and having a first characteristic; and a second set of capillary devices extending from the second surface of the substrate through the substrate and the heater layer device and having a second characteristic different from the first characteristic. The aerosol generating material storage device is in fluid communication with the second surface of the substrate and includes a first aerosol generating material and a second aerosol generating material. The second aerosol generating material has a higher viscosity than the first aerosol generating material, and the first set of capillary devices is configured to impede the flow of the second aerosol generating material.

[0019] According to a fifth aspect of certain embodiments, a heater assembly for an aerosol supply system is provided, the heater assembly comprising: a substrate; a heater layer disposed on at least a first surface of the substrate and configured to generate heat; and one or more capillaries extending from a second surface of the substrate and through the substrate and the heater layer, the one or more capillaries being configured to supply aerosol-generating material from the second surface of the substrate to the heater layer. The heater assembly includes a surface-modified structure configured to regulate the flow of aerosol-generating material capable of flowing along at least a portion of one or more of the surface of the heater layer, the second surface of the substrate, and the side surfaces of one or more capillaries.

[0020] According to some examples of the fifth aspect, surface-modified structures include at least one of surface coatings and surface treatments.

[0021] According to some examples of the fifth aspect, the surface-modified structure is configured to facilitate the flow of aerosol-generating material capable of flowing along at least one of the surfaces of the heater layer, the second surface of the substrate, and the side surfaces of one or more capillaries.

[0022] According to some examples of the fifth aspect, the surface-modified structure is configured to impede the flow of aerosol-generating material that can flow along at least one of the surfaces of the heater layer, the second surface of the substrate, and the side surfaces of one or more capillaries.

[0023] According to some examples of the fifth aspect, the surface modification structure is disposed on at least a portion of the second surface of the substrate and configured to adjust the properties of at least a portion of the second surface of the substrate relative to the flow of an aerosol generating material capable of flowing along the second surface of the substrate.

[0024] According to some embodiments of the fifth aspect, the surface-modified structure is configured to facilitate the flow of aerosol-generating material capable of flowing along a second surface of the substrate, such that the aerosol-generating material can flow toward the openings of one or more capillaries.

[0025] According to some examples of the fifth aspect, the surface-modified structure is configured to impede the flow of aerosol-generating material that can flow along the second surface of the substrate, thereby reducing the flow of aerosol-generating material toward the openings of one or more capillaries.

[0026] According to some examples of the fifth aspect, the surface-modified structure is at least disposed on a portion of the second surface of the substrate surrounding the opening of at least one of the capillaries.

[0027] According to some examples of the fifth aspect, the surface modification structure is disposed on at least a portion of the side surface of one or more capillaries and configured to modulate the characteristics of at least a portion of the side surface of one or more capillaries relative to the flow of aerosol generating material capable of flowing along the side surface of one or more capillaries.

[0028] According to some examples of the fifth aspect, the surface-modified structure is configured to facilitate the flow of aerosol-generating material that can flow along the side surface of one or more capillaries, such that the aerosol-generating material can flow through one or more capillaries at a greater rate.

[0029] According to some examples of the fifth aspect, the surface-modified structure is configured to impede the flow of aerosol-generating material that can flow along the side surface of one or more capillaries, so that the aerosol-generating material can flow through one or more capillaries at a lower rate.

[0030] According to some examples of the fifth aspect, the surface modification structure is disposed on at least a portion of the surface of the heater layer and configured to modulate the properties of at least a portion of the surface of the heater layer relative to the flow of aerosol generating material capable of flowing along the surface of the heater layer.

[0031] According to some examples of the fifth aspect, the surface-modified structure is configured to facilitate the flow of aerosol-generating material that can flow along the surface of the heater layer, such that the aerosol-generating material can flow out from openings in one or more capillaries located in the heater layer.

[0032] According to a sixth aspect of certain embodiments, a consumable is provided for use with an aerosol supply device, the consumable including an aerosol generating material storage portion, an airflow path, and a heater assembly according to a first aspect, wherein the heater assembly is configured such that a second surface of a substrate is provided in fluid communication with the aerosol generating material storage portion, and the heater layer is provided in fluid communication with the airflow path.

[0033] According to a seventh aspect of certain embodiments, an aerosol supply device for use with consumables is provided, the device including an airflow path and a heater assembly according to a fifth aspect, wherein the heater assembly is configured such that a heater layer is provided in fluid communication with the airflow path.

[0034] According to an eighth aspect of certain embodiments, an aerosol supply system is provided, the aerosol supply system including an aerosol generating material storage portion, an airflow path, and a heater assembly according to a fifth aspect, wherein the heater assembly is configured such that a second surface of a substrate is provided in fluid communication with the aerosol generating material storage portion, and the heater layer is provided in fluid communication with the airflow path.

[0035] According to a ninth aspect of certain embodiments, a method is provided for manufacturing a heater assembly for an aerosol supply system, the heater assembly comprising: a substrate; a heater layer disposed on at least a first surface of the substrate and configured to generate heat; and one or more capillaries extending from a second surface of the substrate and through the substrate and the heater layer, the one or more capillaries being configured to supply aerosol generating material from the second surface of the substrate to the heater layer. The method includes: providing a surface modification structure configured to regulate the flow of aerosol generating material capable of flowing along at least a portion of one of a surface of the heater layer, a second surface of the substrate, and a side surface of one or more capillaries.

[0036] According to a tenth aspect of certain embodiments, a heater device for an aerosol supply device is provided, the heater device comprising: a substrate; a heater layer device disposed on at least a first surface of the substrate and configured to generate heat; and a capillary device extending from a second surface of the substrate and through the substrate and the heater layer device, the capillary device being configured to supply aerosol generating material from the second surface of the substrate to the heater layer device, wherein the heater device includes a surface-modified structure device configured to regulate the flow of aerosol generating material capable of flowing along at least a portion of one or more of the surface of the heater layer device, the second surface of the substrate, and the side surface of the capillary device.

[0037] It should be understood that the features and aspects of the invention described above with respect to the first and other aspects of the invention are equally applicable to embodiments of the invention according to other aspects of the invention, and can be suitably combined with embodiments of the invention according to other aspects of the invention, and not only in the specific combinations described above. Attached Figure Description

[0038] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 This is a perspective view of an aerosol supply system according to aspects of this disclosure; Figure 2 It is suitable for Figure 1 An exploded three-dimensional view of the atomizing cartridges used in the aerosol supply system; Figure 3 This is a perspective view of a heater assembly according to an aspect of the present disclosure, wherein the heater assembly includes a substrate, a resistive layer, and a capillary extending through the substrate and the resistive layer; Figure 4 A first implementation of the heater assembly is schematically shown, wherein a first set of capillaries is configured to impede the flow of a second aerosol-generating material, wherein the cross-sectional dimensions (diameter) of the first set of capillaries are set to be different from the cross-sectional dimensions (diameter) of the second set of capillaries. Figure 5 A second implementation of the heater assembly is schematically shown, wherein a first set of capillaries is configured to impede the flow of the second aerosol-generating material, thereby setting the cross-sectional shape of the first set of capillaries to be different from that of the second set of capillaries. Figure 6 A third implementation of the heater assembly is schematically shown, wherein a first set of capillaries is configured to impede the flow of a second aerosol-generating material, thereby the first set of capillaries is provided with a surface-modified structure that alters the properties of the first set of capillaries relative to the properties of the second set of capillaries. Figure 7 This is a method for forming a heater assembly according to aspects of this disclosure; Figure 8a and Figure 8b A first implementation of a heater assembly is schematically shown, the heater assembly including multiple surface modification structures on a second surface of a substrate of the heater assembly, wherein... Figure 8a A top view of the second surface is shown and Figure 8b A perspective view of the heater assembly is shown; Figure 9a and Figure 9b A second and a third implementation of a heater assembly are shown, comprising a surface-modified structure on the side surface through which the capillary of the heater assembly extends, wherein... Figure 9a A cross-sectional view of a heater assembly according to a second implementation is shown, the heater assembly including a fourth surface-modified structure provided at one end of a capillary; and Figure 9b A cross-sectional view of a heater assembly according to a third embodiment is shown, the heater assembly including a fifth surface-modified structure provided at the other end of the capillary. Figure 10a and Figure 10b A fourth embodiment of a heater assembly is schematically illustrated, the heater assembly including a plurality of surface modification structures on the surface of the heater layer of the heater assembly, wherein... Figure 10a A top-down view of the surface of the heater layer is shown, and Figure 10b A perspective view of the heater assembly is shown; and Figure 11 This is a method for forming a heater assembly according to aspects of this disclosure. Detailed Implementation

[0039] This document discusses / describes aspects and features of certain examples and implementations. Some aspects and features of certain examples and implementations can be conventionally implemented, and for the sake of brevity, these aspects and features are not discussed / described in detail. Therefore, it should be understood that aspects and features of the apparatus and methods discussed herein that are not described in detail can be implemented according to any conventional techniques used to implement such aspects and features.

[0040] According to this disclosure, a "non-flammable" aerosol supply system is a system in which the aerosol supply system (or its components) consists of aerosol generating materials that can deliver at least one substance to a user without combustion or by combustion.

[0041] In some embodiments, the non-flammable aerosol supply system is an electronic cigarette, also known as a vapor device, electronic cigarette, or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not required. Throughout the following description, the term "electronic cigarette" is sometimes used, but it is used interchangeably with "aerosol (vapor) supply system."

[0042] In some embodiments, the non-flammable aerosol supply system is a mixing system that uses a combination of aerosol-generating materials to generate aerosols, one or more of which can be heated. Each of these aerosol-generating materials may be in, for example, solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the mixing system includes liquid or gel aerosol-generating materials and solid aerosol-generating materials. Solid aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0043] Aerosol-generating materials are materials capable of generating aerosols, for example, when heated, radiated, or electrified in any other way. Aerosol-generating materials may be in liquid or gel form, and may or may not contain active substances and / or flavorings.

[0044] In some embodiments, the aerosol-generating material may, where appropriate, comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dried gel. An amorphous solid is a solid material in which some fluid (e.g., liquid) can be retained. In some embodiments, the aerosol-generating material may, for example, comprise from about 50 wt%, 60 wt%, or 70 wt% of amorphous solid to about 90 wt%, 95 wt%, or 100 wt% of amorphous solid.

[0045] In some embodiments, the aerosol generating material or each aerosol generating material may comprise one or more active substances and / or flavoring agents, one or more aerosol forming agent materials, and optionally one or more other functional materials.

[0046] In some implementations, the substance to be delivered includes an active substance.

[0047] As used herein, an active substance can be a physiologically active substance, which is a material intended to achieve or enhance a physiological response. Active substances can be, for example, selected from nutritional supplements, nootropics, and psychoactive agents. Active substances can be naturally occurring or synthetically obtained. Active substances may include, for example, nicotine, caffeine, taurine, theophylline, vitamins such as B6 or B12 or C, melatonin, or components, derivatives, or combinations thereof. The active substance may also include one or more components, derivatives, or extracts of tobacco or another plant.

[0048] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0049] As indicated herein, the active substance may include or be derived from one or more plants or their components, derivatives, or extracts. As used herein, the term "plant-based" includes any material derived from a plant, including but not limited to extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, pericarps, shells, etc. Alternatively, the material may include a naturally occurring or synthetically obtained active compound. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, flakes, etc. Examples of plant-based ingredients include tobacco, eucalyptus, star anise, cocoa, fennel, lemongrass, peppermint, spearmint, rooibos tea, chamomile, flaxseed, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, yerba mate, citrus peel, papaya, rose, sage, tea leaves (such as green or black tea), thyme, cloves, cinnamon, coffee, fennel seeds, basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, chili powder, rosemary, saffron, and lavender. Grass, lemon peel, mint, juniper, elderflower, vanilla, holly, perilla, turmeric, sandalwood, coriander, bergamot, orange blossom, myrtle, blackcurrant, valerian, allspice, nutmeg, damiana, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, damiana, guarana, chlorophyll, baobab fruit, or any combination of the above. Mint may be selected from the following mint varieties: wild mint, cultivated mint varieties, nelica mint, peppermint, lemon peppermint cultivar, peppermint cultivar, wrinkled spearmint, heartleaf mint, longleaf mint, champagne mint, pleri mint, spearmint cultivar, and roundleaf mint.

[0050] In some embodiments, the active substance includes or is derived from one or more plants or their components, derivatives or extracts, and the plant is tobacco.

[0051] In some embodiments, the active substance includes or is derived from one or more plants or their components, derivatives or extracts, and the plant is selected from eucalyptus, star anise and cocoa.

[0052] In some embodiments, the active substance comprises or is derived from one or more plants or their components, derivatives or extracts, and the plant is selected from rooibos and fennel.

[0053] In some implementations, the substance to be delivered includes a flavoring agent.

[0054] As used herein, the terms “flavoring agent” and “spice” refer to materials that, where permitted by local regulations, can be used in products for adult consumers to produce a desired taste, flavor, or other sensory experience. These can include naturally occurring flavoring agents, herbal medicines, extracts of herbal medicines, synthetically obtained materials, or combinations thereof (e.g., tobacco, licorice, hydrangea, eugenol, magnolia bark leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise seed, cinnamon, turmeric, Indian flavorings, Asian flavorings, herbs, holly, cherry, berries, red berries, cranberries, peach, apple, orange, mango, Clementine, lemon, lime, tropical fruits, etc.). Papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, mead, bourbon whiskey, Scotch whiskey, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cassava bark, nutmeg, sandalwood, bergamot, geranium, khat, naswat, betel leaf, hookah, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia seed, caraway seed, cognac, jasmine, and more. Orchid, sage, fennel, wasabi, allspice, ginger, coriander, coffee, peppermint oil from any species of the peppermint genus, eucalyptus, star anise, cocoa, lemongrass, rooibos tea, flaxseed, ginkgo, hazelnut, hibiscus, bay leaf, yerba mate, orange peel, rose, tea leaves (such as green or black tea), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint plants, perilla, turmeric, coriander, myrtle, blackcurrant, valerian, allspice, nutmeg skin Damiana, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor blockers, sensory receptor activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclohexylsulfamic acid, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanical ingredients, or breath fresheners. They can be imitations, synthetic or natural ingredients or blends thereof. They can be in any suitable form, such as liquids like oils, solids like powders, or gases.

[0055] In some embodiments, the flavoring agent includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent includes flavoring components of cucumber, blueberry, citrus fruits, and / or cranberry. In some embodiments, the flavoring agent includes eugenol. In some embodiments, the flavoring agent includes flavoring components extracted from tobacco.

[0056] In some embodiments, in addition to or in place of aroma or taste receptors, flavoring agents may include sensory agents designed to achieve a somatosensory sensation, which is typically chemically induced and perceived through stimulation of the fifth cranial nerve (trigeminal nerve), and these sensory agents may include agents that provide heating, cooling, tingling, or numbing effects. Suitable heat-acting agents may be, but are not limited to, vanillyl ethyl ether, and suitable coolants may be, but are not limited to, leucine ethanol, WS-3.

[0057] Aerosol forming agent materials may include one or more components capable of forming aerosols. In some embodiments, the aerosol forming agent material may include one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butanediol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl octanoate, triethyl citrate, glyceryl triacetate, a mixture of diacetates, benzyl benzoate, benzyl acetate, phenyl acetate, glyceryl tribanoate, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0058] One or more other functional materials may include one or more of pH adjusters, colorants, preservatives, adhesives, fillers, stabilizers, and / or antioxidants.

[0059] Aerosol modifiers are substances typically located downstream of the aerosol generation region, configured to modify the generated aerosols, for example, by altering their taste, flavor, acidity, or other characteristics. Aerosol modifiers can be incorporated into aerosol modifier releasing components, operable to selectively release the aerosol modifier.

[0060] Aerosol modifiers may be, for example, additives or adsorbents. Aerosol modifiers may, for example, contain one or more of flavoring agents, coloring agents, water, and carbon adsorbents. Aerosol modifiers may be, for example, solid, liquid, or gel. Aerosol modifiers may be in powder, filament, or granular form. Aerosol modifiers may not contain filter materials.

[0061] Typically, a non-flammable aerosol supply system may include a non-flammable aerosol supply device and consumables for use with the non-flammable aerosol supply device. In some embodiments, this disclosure relates to consumables comprising aerosol-generating materials and configured for use with a non-flammable aerosol supply device. Throughout this disclosure, consumables are sometimes referred to as articles.

[0062] In some implementations, a non-flammable aerosol supply system, such as its non-flammable aerosol supply device, may include a power source and a controller. For example, the power source may be a power supply.

[0063] In some embodiments, a non-flammable aerosol supply system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, nozzles, filters, and / or aerosol modifiers.

[0064] Consumables are articles comprising or composed of aerosol-generating materials, some or all of which are intended to be consumed by the user during use. Consumables may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material delivery component, an aerosol-generating area, a housing, packaging, a nozzle, a filter, and / or an aerosol modifier. Consumables may also include an aerosol generator, such as a heater, which heats the aerosol-generating material to generate an aerosol during use. The heater may, for example, include a combustible material, a material that can be heated by electrical conduction, or a sensor.

[0065] An aerosol generator is an apparatus configured to generate aerosols from an aerosol generating material. In some embodiments, an aerosol generator is a heater configured to subject the aerosol generating material to thermal energy in order to release one or more volatiles from the aerosol generating material to form an aerosol.

[0066] According to one aspect of this disclosure, an aerosol supply system is provided, comprising an aerosol generating material storage region having a first aerosol generating material and a second aerosol generating material, the second aerosol generating material having a higher viscosity than the first aerosol generating material. A heater assembly includes a first set of capillaries and a second set of capillaries configured to transport the liquid aerosol generating material from one side of the heater assembly to a resistive layer acting as an aerosol generator. The first set of capillaries is arranged to impede the flow of the second aerosol generating material. Thus, the heater assembly can be arranged to control the flow of the second aerosol generating material to the resistive layer. This can produce passive control over the ratio of the aerosol formed by the first and second aerosol generating materials, or can influence the characteristics, such as particle size, of the aerosol generated by each of the first and second aerosol generating materials. This can subsequently affect or alter the user experience when using such an aerosol supply system. Furthermore, it should be noted that a single heater assembly can be supplied with two different aerosol-generating materials and can subsequently be configured (by setting appropriate capillaries) to alter the properties of the generated aerosol. This potentially represents a simpler mechanism for changing the ratio / characteristics of the aerosols generated by the two aerosol-generating materials, rather than using a series of heaters, each supplied with a different aerosol-generating material and controlled independently.

[0067] Figure 1An aerosol supply system 1 according to an aspect of the present invention is schematically illustrated. The aerosol supply system 1 includes an aerosol supply device 2 and a consumable 3, shown herein and referred to as a vaporizer cartridge 3. The aerosol supply device 2 and the vaporizer cartridge 3 together form the aerosol supply system 1.

[0068] The atomizing cartridge 3 is configured to engage and disengage from the aerosol supply device 2. That is, the atomizing cartridge 3 is releasably connected to / can be connected to the aerosol supply device 2. More specifically, the atomizing cartridge 3 is configured to engage / disengage from the aerosol supply device 2 along the longitudinal axis L1. The atomizing cartridge 3 and the aerosol supply device 2 are provided with suitable interfaces to allow them to engage / disengage, such as push-fit interfaces, threaded interfaces, etc.

[0069] The vaporizer cartridge 3 includes a reservoir for storing aerosol-generating material. Therefore, the reservoir may also be referred to as an aerosol-generating material storage area or section. In the following, the aerosol-generating material is a liquid aerosol-generating material. This liquid aerosol-generating material (sometimes simply referred to herein as liquid, source liquid, or e-liquid) may or may not contain nicotine in an e-liquid. However, it should be understood that, in accordance with the principles of this disclosure, other flowable liquids and / or aerosol-generating materials (e.g., gels) may be used. For example, when the vaporizer cartridge 3 is depleted, it can be refilled with liquid or removed from the aerosol supply device 2 and replaced with another (full) vaporizer cartridge 3.

[0070] The aerosol supply device 2 includes a power source (such as a rechargeable battery) and control electronics (sometimes referred to as a controller). As described below, the atomizing cartridge 3 includes an electric heater assembly. When the atomizing cartridge 3 is connected to the aerosol supply device 2, the control electronics of the aerosol supply device 2 are configured to supply power to the heater assembly of the atomizing cartridge 3, causing the heater assembly to generate aerosol from the liquid aerosol generating material supplied thereto.

[0071] The control electronics may include various components capable of facilitating / controlling the supply of power to the atomizing cartridge 3. For example, the control electronics may include an airflow sensor (not shown) configured to detect whether a user is inhaling through the aerosol supply system 1 and supply power in response to this detection, and / or a button (not shown) pressed by the user and supplying power in response to this detection. Depending on the configuration of the aerosol supply device 2, the control electronics may control additional functions (e.g., the control electronics may be configured to control / regulate the recharging of the power supply, or facilitate wired or wireless communication with another electronic device (such as a smartphone). The features and functions of the aerosol supply device 2 are not of primary importance to this disclosure.

[0072] Figure 2 It shows that it is suitable for use in Figure 1 An exemplary atomizing cartridge 3 used in an aerosol supply system. From Figure 2 The exploded view shows that the atomizing cartridge 3 is assembled from the following stacked components: outer shell 4, upper clamping unit 5, heater assembly 6, lower support unit 7, and end cap 8.

[0073] The atomizing cartridge 3 has a top end 31 and a bottom end 32 spaced apart along a longitudinal axis L1, which is both the longitudinal axis of the atomizing cartridge and the longitudinal axis of the aerosol supply system 1. The top end 31 of the atomizing cartridge 3 defines a mouthpiece 33 of the aerosol supply system 1 (where users can position their mouths and inhale). The mouthpiece 33 includes a mouthpiece orifice 41, which is located at the center of the top surface 43 at the top end 42 of the housing 4.

[0074] The outer casing 4 includes a circumferential sidewall 44 extending downward from the top end 42 to the bottom end 45 and defining an internal reservoir 46 (which may be referred to as an aerosol generating material storage area) for accommodating liquid aerosol generating material. Prior to assembly of the atomizing cartridge 3, the bottom end 45 of the casing is open; however, after assembly, the bottom end 45 is closed by a plug formed by stacked upper clamping units 5 and lower support units 7, with the heater assembly 6 clamped between the upper clamping units and the lower support units.

[0075] The upper clamping unit 5 is the middle component among these stacked parts. The upper clamping unit 5 includes a block-shaped support leg 51 and an upwardly extending air tube 52. On each side of the air tube 52, the support leg 51 includes a groove 53 that descends from a flat top surface 54 of the support leg 51 to a flat bottom surface. Figure 2 (Not shown in the diagram). At the bottom surface, each groove 53 is open, and specifically opens into an elongated recess formed in the bottom surface, the depth of which substantially matches the size / shape and thickness of the heater assembly 6. The legs 51 are designed to engage with the housing 4 (more specifically, such that the outer circumferential surface of the legs presses against the inner circumferential surface of the housing 4). The legs 51 may have a suitable shape and include suitable sealing elements to reduce or prevent liquid leakage between the outer surface of the legs 51 and the inner surface of the housing 4.

[0076] An air tube 52 extends upward from the bottom of the recess 53 and defines an internal air passage 58. When the upper clamping unit 5 is engaged with the housing 4, the air tube 52 extends to and surrounds the nozzle orifice 41. The housing 4 and / or the air tube 52 may be suitably configured to provide a liquid-proof (and optionally, air-proof) seal between them. As should be understood below, the air / aerosol is intended to pass through and exit the nozzle orifice 41 along the air tube 52, while the space surrounding the air tube 52 and within the housing 4 defines a reservoir 46 for storing liquid aerosol-generating material. Therefore, it should be understood that, apart from the opening of the recess 53, the reservoir 46 is a sealed volume defined by the housing 4, the outer surface of the air tube 52, and the foot 51.

[0077] The lower support unit 7 is in the form of a block having a generally flat top surface 71 and a flat bottom surface 72. A central air passage 73 extends upward from the bottom surface 72 to the top surface 71. On each side of the air passage 73, the block of the lower support unit 7 includes a through hole 74. Figure 2 In the exemplary atomizing cartridge 3, co-molded contact pads 75 in the form of pins are inserted into through holes 74. More specifically, each contact pad 75 is press-fitted in its respective through hole 74. When the heater assembly 6 is clamped between the top surface 71 of the lower support unit 7 and the recess of the bottom surface 55 of the upper clamping unit 5, each contact pad 75 provides an electrical connection path from the bottom surface 72 to the corresponding end of the heater assembly 6.

[0078] Much like the upper clamping unit 5, the lower support unit 7 is designed to engage with the housing 4 (more specifically, such that the outer peripheral surface of the lower support unit 7 presses against the inner peripheral surface of the housing 4). The lower support unit 7 may have a suitable shape and include suitable sealing components to reduce or prevent liquid leakage between the outer surface of the lower support unit 7 and the inner surface of the housing 4. The legs 51 of the upper clamping unit 5 and the lower support unit 7 (in its block form) are combined together to form a plug at the bottom of the sealed reservoir 46.

[0079] like Figure 2 As shown, the atomizing cartridge 3 includes an end cap 8 at its bottom end. The end cap 8 is made of metal and helps to hold the atomizing cartridge 3 in the aerosol supply device 2 when it is inserted into the top of the device, because in this example, the aerosol supply device 2 is provided with a magnet that attracts the metal to the end cap 8. The end cap 8 has a central opening (…). Figure 2The end cap 8 has a bottom wall 81 (not shown). The end cap 8 also has a circumferential sidewall 83 with two opposing cutouts 84 that latch onto corresponding protrusions 49 on the outer surface of the bottom end of the sidewall 44 of the housing 4, such that the end cap 8 has a snap-fit ​​connection to the bottom end of the housing 4. When the end cap 8 is in place, it holds the lower support unit 7, the upper clamping unit 5, and the heater assembly 6 clamped between the lower support unit 7 and the upper clamping unit 5 in place.

[0080] By arranging the lower support unit 7 to form a snap-fit ​​connection with the bottom end of the side wall 44 of the housing 4, the end cap 8 can be omitted (to reduce the number of parts). Furthermore, the atomizing cartridge 3 may be provided with a notch that engages with a protrusion at the top 21 of the main housing 2, providing a releasable connection between the atomizing cartridge and the main housing. However, the manner in which the atomizing cartridge 3 is configured to engage and connect to the aerosol supply device 2 (and subsequently how the aerosol supply device 2 is configured accordingly to engage with the atomizing cartridge 3) is not important to the principles of this disclosure. In any case, the atomizing cartridge 3 is provided with a structure generally referred to as a device interface, which is the portion of the atomizing cartridge 3 that interfaces with the main housing 2 (or the aerosol generating device). In the above example, the device interface may include a metal cap 8 and / or the lower support unit 7, the metal cap including a bottom wall and circumferential side walls 83, and the lower support unit including a bottom surface 72. More generally, the device interface of the vapor cartridge 3 may include any part of the vapor cartridge 3 that is contacted, adjacent to, coupled to, or otherwise connected to the main housing 2.

[0081] When the components of the atomizing cartridge 3 are assembled, there is a complete air passage from the bottom 32 to the top 31 of the atomizing cartridge 3, and this complete air passage is formed by the air passage 73 converging into the air passage 58 and then into the mouthpiece orifice 41. Where the air passage 73 and the air passage 58 meet, the airflow is split as it passes around the side edge of the heater assembly 6.

[0082] See back Figure 1 The top end 21 of the aerosol supply device 2 includes inlet holes 22 located on both sides of the aerosol supply device 2 (one of the two inlet holes 22 is in Figure 1 (See image). Air can enter the inlet hole 22 and flow laterally inward relative to the longitudinal axis L1 so as to enter the bottom end of the air passage 73 of the lower support unit 7 and begin to flow toward the nozzle 33 in the direction of the longitudinal axis L1.

[0083] Furthermore, when the atomizing cartridge 3 has been assembled, the heater assembly 6 is arranged such that its ends are in fluid communication with the recess 53 (or the opening of the recess 53). Therefore, the liquid aerosol generating material in the reservoir 46 can be transferred to both ends of the heater assembly 6 via the recess 53. The liquid aerosol generating material is also allowed to travel along the longitudinal direction of the heater assembly 6 to areas of the heater assembly 6 that are not in direct contact with the reservoir 46, such as areas where the heater assembly is located in the air passage 73 or air passage 58. Any suitable arrangement can be provided to facilitate the longitudinal transport of the liquid. For example, in some implementations, a wicking material (such as cotton or fiberglass) formed as a layer can be disposed between the heater assembly 6 and the upper clamping unit 5, wherein the wicking material contacts the recess 53 and is capable of transporting the liquid aerosol generating material in the longitudinal direction. Alternatively, the heater assembly 6 itself may be formed with one or more pathways allowing the liquid aerosol generating material to be transported along the length of the heater assembly 6. For example, in some implementations, the heater assembly 6 may be formed of a porous substrate (such as sintered material or ceramic) and / or have passages formed along the length of the heater assembly 6 (e.g., by drilling or other machining). Therefore, although Figure 2 Only a portion of the heater assembly 6 is shown in contact with the groove 53, but the liquid is able to travel along the length of the heater assembly.

[0084] Now turn to heater assembly 6, which is a microfluidic heater assembly. Figure 3 The microfluidic heater assembly 6 is shown in more detail.

[0085] The microfluidic heater assembly 6 includes a substrate 62 and a resistive layer 64 disposed on the surface of the substrate 62.

[0086] In this implementation, the substrate 62 is formed of a non-conductive material, such as quartz (silicon dioxide); however, it should be understood that other suitable non-conductive materials, such as ceramics, may be used. As mentioned above, in some implementations, the substrate 62 may be formed of a porous material. The porous substrate 62 may be formed of a naturally porous material (such as a sponge, porous stone, or ceramics, etc.) or of a material that has been processed into a porous state, such as sintered metal or other materials. These materials (naturally formed or processed) have pores or hollow regions that are interconnected and define pathways that follow random or substantially random paths through the material (wherein, substantially in this context, it means that, considering the bulk material of the substrate 62 as a whole, there may be some general tendency in the direction of the path extension (e.g., from left to right), but from the perspective of the liquid / fluid passing through the substrate 62, the path is, for example, a series of random choices of pores or hollow regions). In other implementations, substrate 62 may be considered impermeable or substantially impermeable (where substantially impermeable in this context means that substrate 62 may have a certain degree of fluid (e.g., liquid) absorption; for example, substrate 62 may be able to absorb up to 2% or up to 1% of the total volume of fluid). The manner in which substrate 62 is formed and the materials made therefrom are not of primary significance to the principles of this disclosure.

[0087] The resistive layer 64 is formed of any suitable conductive material, such as a metal or metal alloy, like titanium or nickel-chromium. The resistive layer 64 can be formed on the first surface 62a of the substrate 62 in any suitable manner. For example, the resistive layer 64 can be provided as a film adhered to or otherwise bonded to the first surface 62a of the substrate 62. Alternatively, the resistive layer 64 can be formed by deposition techniques such as chemical or vapor deposition. The manner in which the resistive layer 64 is formed and the materials made therefrom are not of primary importance to the principles of this disclosure.

[0088] The heater assembly 6 is planar and in the form of a rectangular cubic block, elongated along the longitudinal axis L2. The heater assembly 6 has a strip shape and parallel sides. The planar heater assembly 6 has parallel upper and lower main (planar) surfaces, as well as parallel side surfaces and parallel end surfaces, which are referred to herein as the first surface 62a and the second surface 62b of the substrate 62. Figure 3In the illustrated implementation, the heater assembly 6 has a length of 10 mm, a width of 1 mm, and a thickness of 0.12 mm (wherein the thickness of the substrate 62 is approximately 0.10 mm and the thickness of the resistive layer 64 is approximately 0.02 mm). The small size of the heater assembly 6 allows for a reduction in the overall size of the atomizing cartridge 3 and the overall mass of the components of the atomizing cartridge 3. However, it should be understood that in other implementations, depending on the application at hand, the heater assembly 6 may have different dimensions. For example, in some implementations, the heater assembly 6 may be a 3x3 mm chip.

[0089] Along the longitudinal axis L2, the heater assembly 6 has a central portion 67 and a first end 68 and a second end 69. Figure 3 In this design, the length of the central portion 67 (relative to the lengths of the ends 68 and 69) is magnified for visual clarity. When the vaporizer is in place in the atomizing cartridge, the central portion 67 is located in the air passage 73. The central portion 67 extends across the top of the air passage 73 of the lower support unit 7 and across the bottom of the air passage 58 of the upper clamping unit 5. The ends 68 and 69 are clamped between the upper clamping unit 5 and the lower support unit 7.

[0090] Multiple capillaries 66 are provided in the central portion 67 of the heater assembly 6. Figure 3 Only the opening of the capillary 66 is shown (and enlarged for clarity), but the capillary 66 extends from one side of the heater assembly 6 to the other. More specifically, the capillary extends from the second surface 62b of the substrate 62, through the first surface 62a of the substrate 62 toward the substrate 62 where the resistive layer 64 is disposed, and then through the resistive layer 64. Multiple capillaries 66 extend substantially linearly through the heater assembly 6 (i.e., the capillary 66 follows a substantially linear path). Essentially, this means that the straightness of the path followed by the capillary 66 is within 5%, 2%, or 1%. This measurement can be obtained in any suitable manner, for example, by comparing the length of the distance along the extent of the capillary 66 from the first point to the second point with the corresponding distance the central axis of the capillary 66 extends between the same two points. The capillary 66 is formed in the heater assembly 66 via a manufacturing process. That is, the capillary 66 is not naturally present in the substrate material 62 or the resistive layer 64, but is formed in the substrate material 62 and the resistive layer 64 by appropriate processes. A suitable process for forming capillary 66 (especially when forming capillary 66 that follows a substantially linear path) is laser drilling. However, any other suitable technique may be used to produce capillary 66.

[0091] Capillary 66 is configured to transport liquid from one surface of heater assembly 6 (i.e., the second surface 62b of substrate 62) to resistive layer 64. Capillary 66 may be formed in part based on the liquid stored in reservoir 46 of atomizing cartridge 3 and subsequently used with heater assembly 6, as will be explained in more detail below. However, broadly speaking, in some implementations, capillary 66 may have a diameter of approximately tens of micrometers, for example, between 10 µm and 100 µm. However, it should be understood that in other implementations, capillary 66 may be configured differently.

[0092] See back Figure 2 This illustrates that the heater assembly 6 is positioned between the upper clamping unit 5 and the lower support unit 7. Specifically, the heater assembly 6 is oriented such that the resistive layer 64 faces the lower support unit 7, while the substrate 62 (and specifically the second surface 62b) faces the upper clamping unit 5. Figure 2 It should be understood that the ends 68, 69 of the heater assembly 6 overlap with the through-hole 74 and the contact pad 75. More specifically, the resistive layer 64 is configured to contact the contact pad 75, and therefore the ends 68, 69 of the resistive layer 64 are used to form an electrical connection with the contact pad 75 (and therefore with any power source subsequently attached to the contact pad 75, such as from the aerosol supply device 2). For example, the aerosol supply device 2 may have two power pins (not shown) that contact the bottom end of the contact pad 75. The top end of the contact pad 75 is in electrical contact with the heater assembly 6, as described above. In use, the power supplied by the power source of the aerosol supply device 2 passes through the resistive layer 64 by means of the electrical connection between the ends 68, 69 and the contact pad 75 to cause heating of the resistive layer 64. The resistive layer 64 may therefore be referred to as the heater layer 64. The amount of heating achieved (i.e., the temperature of the resistive layer 64 that can be reached) may depend in part on the power supplied by the aerosol supply device 2 and the resistance of the resistive layer 64. Similarly, the amount of heating (i.e., the temperature required to evaporate the liquid supplied to the resistive layer 64) will depend in part on the properties of the liquid supplied to the resistive layer 64. Therefore, the resistance of the resistive layer 64 can be set based on the specific application at hand, and thus the resistance of the resistive layer 64 can depend on the material of the resistive layer 64 and the physical dimensions of the resistive layer 64 (e.g., thickness).

[0093] According to the principles of this disclosure, an aerosol supply system 1 is configured to simultaneously store (at least) two different aerosol generating materials, and subsequently, a heater assembly 6 (or more specifically, its atomizing cartridge 3) for use in the aerosol supply system 1 is configured to atomize the different aerosol generating materials. Different aerosol generating materials refer to aerosol generating materials having at least one different characteristic, particularly the viscosity of the aerosol generating materials. In particular, the second aerosol generating material has a higher viscosity than the first aerosol generating material. This can be achieved, for example, by providing aerosol generating materials with different components and / or component ratios. For example, the first aerosol generating material may comprise a liquid containing nicotine, a first flavoring agent, and a mixture of propylene glycol and glycerin in a first ratio, while the second aerosol generating material may comprise a liquid containing a different second flavoring agent and a mixture of propylene glycol and glycerin in a second ratio. The viscosity of the aerosol generating materials can be different, partly due to the different ratios of propylene glycol and glycerin. For example, a liquid formulation primarily containing water as a major component (by weight) may have an average dynamic viscosity in the range of 0.005 to 0.007 Pa s, measured at 25°C. A liquid formulation containing about 65 wt% propylene glycol may have an average dynamic viscosity in the range of 0.088 to 0.174 Pa s, while a liquid formulation containing about 50 wt% propylene glycol may have an average dynamic viscosity in the range of 0.100 to 0.216 Pa s. Viscosity is a measure of a fluid's resistance to deformation at a given rate. Therefore, it can be said that a more viscous aerosol-generating material (i.e., a higher average dynamic viscosity) tends to face greater flow resistance and thus flows at a slower rate overall compared to a less viscous material. It should be understood that the above are merely examples of liquid formulations and their viscosities, and this disclosure should not be considered limited to the liquid formulations or viscosities indicated above.

[0094] In some examples, the liquid formulation may contain 50% water and 50% glycerol by weight. For such a formulation, a dynamic viscosity of 0.00525 Pa s is measured at 25°C. When a flavoring agent is added to the liquid formulation, the liquid formulation may contain between 35-50% water by weight, between 35% and 50% glycerol by weight, and between 0 and 30% flavoring agent components by weight. In addition to any flavoring components, the flavoring agent components may contain a solvent (such as propylene glycol). The dynamic viscosity of such a formulation is at least 0.00525 Pa s at 25°C. It should be noted that the weight percentage of water has a large effect on the measured dynamic viscosity, and the expected dynamic viscosity is increased by decreasing the weight percentage of water. In some examples, the liquid formulation may include an active ingredient and / or functional materials. In such cases, the weight percentages of the components listed above vary depending on the amount of the active ingredient and / or functional materials.

[0095] In some other examples, the liquid formulation may contain 60% by weight propylene glycol and 40% by weight glycerol. For such a formulation, the dynamic viscosity is measured at 25°C to be 0.155 Pa s. When a flavoring agent is added to the liquid formulation, the liquid formulation may contain 40% by weight glycerol, 30% to 60% by weight propylene glycol, and 0 to 30% by weight flavoring agent component. In addition to any flavoring components, the flavoring agent component may contain a solvent (such as propylene glycol). The dynamic viscosity of such formulations is at least 0.1 Pa s at 25°C, and may be in the range of 0.10-0.17 Pa s at 25°C. In some examples, the liquid formulation may include an active ingredient and / or functional materials. In such cases, the weight percentages of the components listed above vary depending on the amount of the active ingredient and / or functional materials. For example, a particular liquid formulation contains 30% flavoring agent component, 30% propylene glycol, 36.8% glycerol, 1.7% nicotine, and 1.5% of one or more acids. The formulation was observed to have a dynamic viscosity of 0.1496 Pa·s at 25°C.

[0096] In some other examples, the liquid formulation may contain 50% by weight propylene glycol and 50% by weight glycerol. For such a formulation, the dynamic viscosity is measured at 25°C to be 0.2045 Pa s. When a flavoring agent is added to the liquid formulation, the liquid formulation may contain 50% by weight glycerol, 20% to 50% by weight propylene glycol, and 0 to 30% by weight flavoring agent component. In addition to any flavoring components, the flavoring agent component may contain a solvent (such as propylene glycol). The dynamic viscosity of such formulations is at least 0.2 Pa s at 25°C.

[0097] Different aerosol generating materials are stored in the reservoir 46 of the atomizing cartridge 3. In some implementations, the reservoir 46 may include partition walls dividing the reservoir 46 into multiple independent chambers. For example, see reference... Figure 2 The central air duct 52 can act as a partition wall to separate the left and right sides of the reservoir 46, such that when the atomizing cartridge 3 is assembled, the central air duct 52 is used to keep the left and right sides of the reservoir 46 separated. Therefore, the first aerosol generating material can be disposed on the left side of the container 46, and the second aerosol generating material can be disposed on the right side of the container 46. However, in other implementations, if the two aerosol generating materials are immiscible, the two aerosol generating materials can be disposed in the same reservoir 46 (or alternatively in both the left and right sides of the reservoir 46).

[0098] It should be understood that the reservoir 46 is in fluid communication with the heater assembly 6 via the groove 53. Liquid aerosol generating material exiting the reservoir 46 through the groove 53 is transferred to the capillary 66 (potentially also via a wicking material disposed between the heater assembly 6 and the upper clamping unit 5). The liquid aerosol generating material can then be transferred from the surface of the substrate 62 to the resistive layer 64 by capillary action, where it is subsequently evaporated. However, it should be understood that whether the liquid aerosol generating material passes through the capillary 66 and the rate at which it is transferred from one end of the capillary 66 to the other can depend on a variety of factors.

[0099] According to this disclosure, the heater assembly 6 is provided with a first set of one or more capillaries 66 and a second set of one or more capillaries 66. The first set of one or more capillaries has a first characteristic and extends from the second surface 62b of the substrate 62 through the substrate 62 to the resistive layer 64. The second set of one or more capillaries also extends from the second surface 62b of the substrate 62 through the substrate 62 to the resistive layer 64, but has a second characteristic different from the first characteristic. Therefore, based on the difference between the first and second characteristics, the first set of one or more capillaries 66 is configured to impede the flow of the second aerosol generating material. More specifically, the first set of capillaries 66 is configured to impede (or in some cases prevent) the flow of the second aerosol generating material through the first set of capillaries 66, such that a smaller amount (or in some cases no amount) of the second aerosol generating material flows through the first set of capillaries 66 to the resistive layer 64.

[0100] A first set of capillaries and a second set of capillaries 66 are provided, wherein the first set of capillaries 66 is configured to impede the flow of the second aerosol-generating material through the first set of capillaries 66. This means that the heater assembly 6 can passively control the flow of the second aerosol-generating material to the resistive layer 64 of the heater assembly 6, and thus control the vaporization of the second aerosol-generating material. It should be understood that although the first set of capillaries 66 is configured to impede the flow of the second aerosol-generating material, the second set of capillaries 66 is correspondingly configured to facilitate the flow of the second aerosol-generating material. That is, the second aerosol-generating material can flow through the second set of capillaries 66. Therefore, the second set of capillaries 66 can be suitably configured not to impede (or at least to a lesser extent impede) the flow of the second aerosol-generating material through the second set of capillaries 66.

[0101] Therefore, the flow of the second aerosol generating material to the resistive layer 64 can be controlled in at least two ways. In one example, the rate and / or amount of the second aerosol generating material can be controlled by the heater assembly 6. For example, the amount and / or rate at which the second aerosol generating material is supplied to the resistive layer 64 can be controlled by changing the number of the second set of capillaries 66. For example, a relatively large number of the second set of capillaries 66 allows a relatively large amount of the second aerosol generating material to be supplied to the resistive layer 64 and vaporized. This means that the aerosol generated and supplied to the user via the nozzle orifice has an increased amount of the second aerosol generating material. Furthermore, it should be understood that this can change the proportion of aerosol formed by the second aerosol generating material to the proportion of aerosol formed by the first aerosol generating material. For example, increasing the number of the second set of capillaries 66, thereby allowing a relatively large amount of the second aerosol generating material to be supplied to the resistive layer 64 and vaporized, would mean that a larger proportion of aerosol is supplied by the second aerosol generating material compared to, for example, a case where the number of the second set of capillaries 66 is relatively low. Note that the second capillary 66 may also allow the first aerosol-generating material to travel through it. That is, the second set of one or more capillary tubes 66 is configured to allow the first and second aerosol-generating materials to flow along the second set of one or more capillary tubes 66. Therefore, in some examples, the generated aerosol can have any ratio between the aerosol generated by the first aerosol-generating material and the aerosol generated by the second aerosol-generating material, ranging from 1:1 (i.e., 50% from the first aerosol-generating material and 50% from the second aerosol-generating material) to 1:0 (i.e., 100% from the first aerosol-generating material) (excluding endpoint values). For example, the heater assembly 6 can be configured to provide a ratio between 1:0.99 and 1:0.01 (including endpoint values).

[0102] Therefore, heater assembly 6 can be configured to provide the user with aerosols generated from a first aerosol-generating material and aerosols generated from a second aerosol-generating material in different proportions. This affects the composition of the aerosol delivered via heater assembly 6 and the subsequent user perception.

[0103] In another example, a first set of capillaries and a second set of capillaries 66 are provided with different characteristics. These different characteristics affect the extent to which a more viscous second aerosol-generating material can flow through the first set of capillaries 66. This could mean that the second aerosol-generating material (additionally or alternatively) can be selectively supplied to specific locations on the resistive layer 64 for vaporization. This can have an impact on the aerosol generated and subsequently delivered to the user via orifice 41, and therefore also on the user experience. That is, the heater assembly 6 can be configured such that the first aerosol-generating material, when atomized by the resistive layer 64, produces an aerosol with different characteristics compared to the second aerosol-generating material when atomized by the resistive layer 64.

[0104] In some examples, during the use of the heater assembly 6, i.e., when current is applied to the resistive layer 64 of the microfluidic heater assembly 6, the temperature reached across the resistive layer 64 may be non-uniform. That is, different regions of the resistive layer 64 may reach higher temperatures during operation than other regions of the resistive layer 64. These regions of the resistive layer 64 with relatively higher temperatures may be referred to as “hot spots” of the resistive layer 64. These “hot spots” may be the result of one or more characteristics of the heater assembly 6 and / or the atomizing cartridge 3 (e.g., airflow passing through the heater assembly 6). For example, “hot spots” may be generated due to the application of current to the resistive layer 64, thereby variations in the current flow across the resistive layer 64 and / or variations in the resistance of the resistive layer 64 may cause certain regions of the resistive layer 64 to reach higher temperatures than other regions. For example, hot spots may appear in the central region of the central portion 67 of the heater assembly 6. That is, for the central portion 67, the central region of the central portion 67 may be at a generally higher temperature during operation than the outer or peripheral regions surrounding the central region of the central portion 67. More generally, the resistive layer 64 may be configured such that one or more regions of the resistive layer 64 have different operating characteristics (i.e., temperature) compared to the rest of the resistive layer 64.

[0105] Therefore, in some examples, the heater assembly 6 can be configured such that the second aerosol generating material is supplied to these "hot spots" (e.g., the central region of the central portion 67 of the resistive layer 64). That is, a first set of capillaries 66 that impedes the flow of the second aerosol generating material can be positioned around the central region of the central portion 67 (i.e., in the peripheral region of the central portion 67), while a second set of capillaries 66 that allows the second aerosol generating material to flow through can be positioned in the central region of the central portion 67 relative to the first set of capillaries 66. Thus, the second aerosol generating material can typically be atomized at a slightly higher temperature by being guided to the "hot spots" of the heater assembly 6. This can subsequently affect the aerosol generated by the second aerosol generating material when vaporized by the resistive layer 64, for example, in terms of particle size, etc. For example, generally speaking, a higher aerosolization temperature should be understood as typically forming aerosols with a smaller particle size.

[0106] Alternatively, it should be understood that in some implementations, the second aerosol-generating material can be directed to the cooler periphery region of the central portion 67 of the heater assembly 6 (e.g., by providing a first set of capillaries 66 in the central region of the central portion 67 of the heater assembly 6). Furthermore, this can subsequently affect the aerosol generated by the second aerosol-generating material when vaporized by the resistive layer 64, for example, in terms of particle size. For instance, generally speaking, a lower aerosolization temperature should be understood as typically forming aerosols with a larger particle size.

[0107] It should also be understood that in some implementations, the second aerosol-generating material can be selectively provided to regions of the heater assembly 6, regardless of the operating temperature of the resistive layer 64. That is, there may be other reasons to direct the second aerosol-generating material to certain locations in the heater assembly 6, which may affect the properties of the generated aerosol. See, for example, [link to relevant documentation]. Figure 2 The air flowing through the central air passage 73 is diverted around the longitudinal edge of the heater assembly 6. This can mean, for example, that there is relatively less turbulence in the airflow near the longitudinal edge of the heater assembly 6 than in the central region of the central portion 67. More turbulence can result in larger particle sizes for any aerosols generated in this region (e.g., due to longer residence times and / or greater coalescence opportunities). Therefore, depending on the desired outcome, the second aerosol-generating material can be directed to the edge of the resistive layer 64 (by arranging the first set of capillaries in the central region of the central portion 67) or to the center of the resistive layer 64 (by arranging the first set of capillaries 66 in the peripheral region of the central portion 67).

[0108] Therefore, more generally, a first set of one or more capillaries 66 is disposed in one (or more) regions of the heater assembly 6 such that it impedes or prevents the supply of the second aerosol generating material to the resistive layer 64 in one or more regions of the heater assembly 6. This may be because different operating characteristics of the heater assembly 6 are observed in different regions of the resistive layer 64, due to the configuration of the heater assembly 6 itself (such as the resistance of the resistive layer 64 in its different regions) or due to the configuration of the atomizing cartridge 3 / aerosol supply system 1 (such as in terms of the airflow flowing toward / across / through the heater assembly 6). By selectively supplying the second aerosol generating material to certain regions of the resistive layer 64, a desired aerosol generated by the second aerosol generating material can be generated.

[0109] Therefore, it should be understood that providing a heater assembly 6 with a first set of capillaries and a second set of capillaries 66 allows the heater assembly 6 (i.e., a single heater assembly 6) to generate aerosols simultaneously from both the first aerosol generating material and the second aerosol generating material in a controlled manner. Specifically, one or both of the relative proportion of the aerosol formed by the second aerosol generating material and the characteristics of the aerosol formed by the second aerosol generating material can be controlled or set based on the appropriate arrangement of the first set of capillaries and the second set of capillaries 66. Thus, the characteristics of the resulting aerosol can be appropriately configured to achieve specific results, such as flavoring mixing or targeted delivery to the user by particle size.

[0110] According to this disclosure, the first group of one or more capillaries 66 differs from the second group of one or more capillaries 66 in at least one of the following: the dimensions of the cross-section of the capillaries 66, the shape of the cross-section of the capillaries 66, and the nature of the side surfaces of the one or more capillaries 66. However, it should be understood that in other implementations, the first group of capillaries 66 may differ from the second group of capillaries 66 in any suitable respect, provided that it subsequently impedes the flow of the second aerosol-generating material along the first group of capillaries 66.

[0111] Figures 4 to 6 Three examples of heater assembly 6, respectively, provided according to the principles of this disclosure, are illustrated.

[0112] Figure 4 and Figure 5 A portion of the central portion 67 of the heater assembly 6 is shown as viewed from above (i.e., looking down at the resistive layer 64). A first set of multiple capillaries 66a is shown distributed throughout the central portion 67 of the heater assembly 6, wherein, as described above, the first set of capillaries 66a extends through the second surface 62b of the heater assembly 6 (i.e., the surface opposite the resistive layer 64) and has a first characteristic. Figure 4 and Figure 5 A second set of multiple capillaries 66b is also shown disposed in the central region 67a of the central portion 67 of the heater assembly 6. The central region 67a is indicated by dashed lines. As described above, the second set of capillaries 66b extends through the second surface 62b of the heater assembly 6 (i.e., the surface opposite the resistive layer 64) and has a second characteristic different from the first characteristic.

[0113] Figure 4 This represents a first example of a heater assembly 6 according to the present invention.

[0114] exist Figure 4 In this case, the cross-sectional dimensions of the first group of capillary tubes 66a are different from those of the second group of capillary tubes 66b. Figure 4 In the example, the cross-sectional shape of both the first set of capillaries 66a and the second set of capillaries 66b is circular. However, the diameter of the second set of capillaries 66b is larger than the diameter of the first set of capillaries 66a (alternatively, the diameter of the first set of capillaries 66a is smaller than the diameter of the second set of capillaries 66b). It should be understood that in other implementations, the cross-sectional shapes of capillaries 66a and 66b may be different, such as square or hexagonal, and in this case, at least one dimension of the cross-section of the second set of capillaries 66b may be different (i.e., larger) than the equivalent dimension of the first set of capillaries 66a.

[0115] As mentioned above, several factors can influence how the liquid aerosol-generating material interacts with the capillary and subsequently affects the capillary forces experienced by the aerosol-generating material. One of these factors is the size of the cross-sectional area of ​​the capillary 66, or in Figure 4 In the context of this example, the diameter of capillary 66 is considered. Note that the second aerosol-generating material is more viscous than the first aerosol-generating material. By appropriately setting the diameter of the first set of capillary 66a to a sufficiently small value, the more viscous second aerosol-generating material may not be able to sufficiently penetrate into the first set of capillary 66a (e.g., the surface tension of the second aerosol-generating material may prevent or reduce the chance of the second aerosol-generating material entering the first set of capillary 66a). Therefore, as described above, by setting the diameter of the first set of capillary 66a to a suitable (i.e., sufficiently small) value, the first set of capillary 66a can be configured to impede the flow of the second aerosol-generating material through the first set of capillary 66a.

[0116] Furthermore, it should be understood that the dimensions (i.e., diameter) of the first set of capillaries 66a are also configured to appropriately allow the first aerosol-generating material to enter and pass through the first set of capillaries 66a. In other words, the dimensions / diameter of the first set of capillaries 66a are set small enough to impede the flow of the second aerosol-generating material therethrough, but large enough to allow the first aerosol-generating material to enter and pass through the first set of capillaries 66a. Additionally, it should be understood that the second set of capillaries 66b has dimensions (i.e., diameter) configured to appropriately allow the second aerosol-generating material to penetrate and pass through the second set of capillaries 66b.

[0117] exist Figure 4 In the example, the second set of capillaries 66b is disposed in the first region 67a of the central portion 67 of the heater assembly 6. Therefore, based on the above, it should be understood that the second aerosol generating material can pass through the second capillaries 66b to reach the resistive layer 64 in the first region 67a, but is blocked or substantially blocked from reaching areas outside the first region 67a of the resistive layer 64 (wherein, substantially in this text, it means that a small amount of the second aerosol generating material can pass through the second capillaries 66b relative to the first aerosol generating material; for example, the ratio of the first aerosol generating material to the second aerosol generating material is 10:1 or greater). Thus, the second aerosol generating material is primarily supplied to the first region 67a, which may correspond to, for example, a hot spot of the resistive layer 64. Alternatively, although not shown, it should be understood that in other implementations, the second set of capillaries 66b may be distributed differently (e.g., uniformly) across the entire central portion 67.

[0118] Therefore, by setting the dimensions of the cross-sections of capillaries 66a and 66b, the supply of the second aerosol generating material to the resistive layer 64 can be controlled or set accordingly.

[0119] Figure 5 A second example of heater assembly 6 according to this disclosure is shown.

[0120] exist Figure 5 In this case, the cross-sectional shape of the first group of capillaries 66a is different from the cross-sectional shape of the second group of capillaries 66b. Figure 5 In the example, the first set of capillary tubes 66a has a circular cross-sectional shape. However, in this case, the second set of capillary tubes 66b has a triangular cross-sectional shape. It should be understood that in other implementations, the cross-sectional shapes of the first set of capillary tubes 66a and the second set of capillary tubes 66b may differ from those shown, for example, squares or hexagons, etc.

[0121] As mentioned above, several factors can influence how the liquid aerosol generating material interacts with the capillary and subsequently affects the capillary forces experienced by the aerosol generating material. Not only the dimensions of the capillary 66's cross-section, but also, in some cases, the shape of the cross-section, can affect whether the liquid aerosol generating material can flow along the capillary 66. Figure 5 In the example, the shape and diameter of the first set of capillaries 66a are configured such that the more viscous second aerosol-generating material cannot sufficiently penetrate into the first set of capillaries 66a (e.g., the surface tension of the second aerosol-generating material can prevent or reduce the chance of the second aerosol-generating material entering the first set of capillaries 66a). Therefore, as described above, by setting the shape and / or diameter of the first set of capillaries 66a to an appropriate (i.e., sufficiently small) value, the first set of capillaries 66a can be configured to impede the flow of the second aerosol-generating material through the first set of capillaries 66a.

[0122] exist Figure 5 In the example, the second set of capillaries 66b has a triangular cross-sectional shape. Different cross-sectional shapes of the capillaries can exert different capillary forces on the liquid aerosol-generating material that can pass through the capillaries 66, and furthermore, this cross-sectional shape interacts with the surface tension of the liquid aerosol-generating material in a certain way. In other words, due to its cross-sectional shape, the shape of the capillaries 66 is sufficient to allow the aerosol-generating material to enter the capillaries 66. Figure 5 In this embodiment, a second capillary 66b is provided to allow the second aerosol-generating material to enter the capillary 66b. Alternatively, in other examples, the cross-sectional shape of the first capillary 66a may be triangular, etc. The precise shape and size may depend on the properties of the aerosol-generating material used and whether the first set of capillary tubes 66a can impede the flow of the second aerosol-generating material along the first set of capillary tubes 66a.

[0123] and Figure 4 Similarly, in Figure 5 In this embodiment, a second set of capillaries 66b is disposed in a first region 67a of the central portion 67 of the heater assembly 6. Therefore, similarly, the second aerosol-generating material can pass through the second capillaries 66b to reach the resistive layer 64 in the first region 67a, but is prevented or substantially prevented from reaching areas outside the first region 67a of the resistive layer 64 (wherein, in this text, "substantially again" again means that a small amount of the second aerosol-generating material can pass through the second capillaries 66b relative to the first aerosol-generating material; for example, the ratio of the first aerosol-generating material to the second aerosol-generating material is 10:1 or greater). Alternatively, although not shown, it should be understood that in other implementations, the second set of capillaries 66b may be distributed differently (e.g., uniformly) throughout the central portion 67.

[0124] Therefore, by setting the cross-sectional shape of capillaries 66a and 66b, the supply of the second aerosol generating material to the resistive layer 64 can be controlled or set accordingly.

[0125] Figure 6 This represents a third example of heater assembly 6 according to the present disclosure.

[0126] Figure 6 A cross-section of an exemplary heater assembly 6 is schematically shown. For the purposes of this example, two capillaries 66a, 66b are shown, but it should be understood that, in practice, the heater assembly 6 may include more than two capillaries 66a, 66b. It can be seen that the capillaries 66a, 66b extend from the second surface 62b of the substrate 62 through the resistive layer 64.

[0127] When considering the heating assembly 6 of this disclosure, it should be understood that liquid is supplied to the resistive layer 64 via capillaries 66a and 66b. The liquid in contact with these surfaces has a specific contact angle associated with the respective surface. The liquid flow properties of the surfaces can also be set or changed by altering or setting the contact angle of a given liquid aerosol generating material relative to the aforementioned surfaces.

[0128] exist Figure 6 In the example, the first set of capillaries 66a and the second set of capillaries 66b may have the same or similar cross-sectional shape and size, but the first set of capillaries 66a has a surface modification structure 91 provided along its sidewall. The surface modification structure 91 is configured to regulate (i.e., set or change) the flow of aerosol-generating material that can flow along the sidewall of the first set of capillaries 66a. Figure 6In the example, the surface modification structure 91 is configured to impede (i.e., reduce) the rate of liquid flow along the respective surface relative to a surface or surface portion not containing the surface modification structure 91. In conjunction with the diameter (size) and / or shape of the first set of capillaries 66a, the surface modification structure 91 may be configured to impede or substantially impede the flow of the second aerosol generating material along the second capillary 66b (wherein, in this text, substantially again means that a small amount of the second aerosol generating material is able to pass through the second capillary 66b relative to the first aerosol generating material; for example, the ratio of the first aerosol generating material to the second aerosol generating material is 10:1 or greater). In other words, in the absence of surface modification structure 91 (e.g., in the second set of capillaries 66b), both the first and second aerosol generating materials are able to flow into and along the capillaries; however, in the presence of surface modification structure 91, for example in the first set of capillaries 66a, the surface energy of the sidewalls of the first set of capillaries 66a is changed to such an extent that the second aerosol generating material can no longer enter or pass through the first set of capillaries 66a, while the first aerosol generating material can still enter and pass through the first capillaries 66a (albeit potentially at a reduced rate).

[0129] Therefore, by modifying the surface of the first set of capillaries 66a via the surface modification structure 91, the first set of capillaries 66a can be configured to substantially impede the flow of the second aerosol generating material through the first set of capillaries 66a.

[0130] It should also be understood that in some other implementations, the surface modification structure 91 may alternatively be disposed on the second set of capillaries 66b and configured to increase (i.e., enhance) the rate of liquid flow along the respective surface relative to the surface or portion of the surface that does not include the surface modification structure 91. In such an implementation, the surface modification structure 91 is configured to effectively enable the capillaries 66b, which would otherwise impede the flow of the second aerosol-generating material.

[0131] Surface modification structures can modify the surface of the underlying bulk material (e.g., substrate 62) in any suitable way to alter the surface properties (e.g., surface energy) in the region where the surface modification structure is disposed. In some embodiments, the surface modification structure includes a surface coating. For example, a surface coating of another material can be applied to the surface of substrate 62 and / or the resistive layer. In other implementations, the surface modification structure includes a surface treatment. A surface treatment is any treatment performed on the corresponding surface of the heater assembly 6 (e.g., substrate 62) that subsequently alters the surface properties (such as surface energy) of the bulk material. For example, a surface treatment may include etching, scoring, or any other similar treatment that roughens the surface. In other examples, a surface treatment may include polishing or otherwise smoothing the surface of the heater assembly 6.

[0132] Therefore, by providing a surface modification structure 91 on the surfaces of capillaries 66a and 66b, the supply of the second aerosol generating material to the resistive layer 64 can be controlled or set accordingly.

[0133] Figures 4 to 6 Three examples are shown of how the first set of capillaries 66a and the second set of capillaries 66b can be configured such that the first set of capillaries 66a impedes the flow of the more viscous second aerosol-generating material, while the second set of capillaries 66b allows the flow of the second aerosol-generating material. As mentioned above, the way the liquid interacts with the capillaries 66a, 66b can depend on several factors. Therefore, in the process of constructing the first set of capillaries 66a to impede the flow of the more viscous second aerosol-generating material, Figures 4 to 6 Any one or more of the techniques described herein can be used in combination to achieve the desired results. Furthermore, it should be understood that the precise manner in which the first set of capillary tubes 66a and / or the second set of capillary tubes 66b are configured can depend in part on the properties of the first and second aerosol-generating materials to be used with the heater assembly 6. A suitable configuration can be found through empirical testing and / or computer simulation.

[0134] The heater assembly 6, as described above, is typically configured as a relatively small component with a relatively small coverage area (compared to more conventional heater assemblies such as wicks and coils). This is partly because the capillary 66 is formed via a manufacturing process within the heater assembly 6 (i.e., the capillary is machined, for example, by a laser drilling process), and can therefore be designed to achieve the desired delivery of liquid aerosol generating material to the resistive layer 64. By providing a smaller component, material waste can be reduced (e.g., when the atomizing cartridge 3 is discarded). Not only can the liquid be delivered to the resistive layer 64 more efficiently, but by manufacturing the capillary 66, more control is provided over the supply of liquid to the resistive layer 64 (i.e., the more capillaries of a given diameter, the more liquid (ml / s) can be delivered to the resistive layer 64 per unit time).

[0135] It should be understood that the configuration providing the atomizing cartridge 3 housing the heater assembly 6 is an exemplary configuration of such atomizing cartridge 3. The principles of this disclosure also apply to other configurations of the atomizing cartridge 3 (e.g., including those with...). Figure 1 and Figure 2 Components that are similar to or different from the components shown, and those that are... Figure 2(The arrangements shown may be similar or different layouts). That is, the relative positions of the atomizing cartridge 3 and the heater assembly 6 within the atomizing cartridge 3 are not important to the principles of this disclosure. Broadly speaking, the atomizing cartridge may include a top (with a mouthpiece orifice 41) and a bottom. In the example shown above, the heater assembly 6 is arranged below the reservoir 46, horizontal or substantially horizontal (e.g., within 5°) to the longitudinal axis of the atomizing cartridge 3, and arranged in an airflow path substantially perpendicular to the longitudinal axis of the heater assembly. However, this is not necessarily the case, and in other implementations, the atomizing cartridge 3 may be configured differently depending on the specific design and application. For example, the heater assembly 6 may be arranged such that the airflow is parallel or substantially parallel to the longitudinal axis of the heater assembly (e.g., within 5°), for example, along the exposed surface of the resistive layer 64. For example, the upper clamping unit 5 may not have a central air passage 58, but rather the air passage may be provided on one side of the upper clamping unit 5. Air can enter the atomizing cartridge 3 through a suitable inlet, flow along the longitudinal surface of the heater assembly 6 (and along the resistive layer 64), and then pass vertically or substantially vertically (e.g., within 5° of the vertical direction) through an air passage 58 located at one end of the upper sealing unit 5 (e.g., the end opposite the air inlet). The housing 4 and the mouthpiece orifice 41 can be suitably constructed. In such an example, the entire lower surface of the heater assembly 6 can be exposed to the reservoir 46. In this implementation, the capillary 66 can be distributed throughout the heater assembly 6, not just within the central portion 67 of the heater assembly 6 (assuming the resistive layer 64 can be connected to a power source). Therefore, although already... Figure 1 and Figure 2 The heater assembly 6 is described in the specific text of the exemplary atomizing cartridge 3, but the principles described herein can be applied to different heater assemblies used in different atomizing cartridges 3.

[0136] exist Figure 2 In the example shown, contact pad 75 directly contacts the resistive layer 64 of the heater assembly 6. However, the atomizing cartridge 3 can be arranged in any suitable manner to facilitate electrical contact between the aerosol supply device 2 and the heater assembly 6. For example, in some implementations, wires or other conductive elements may extend between the resistive layer 64 of the atomizing cartridge 3 and the contact pad 75. This may be especially true when the maximum dimension of the heater assembly 6 (e.g., its length) is less than the minimum distance between the contact pads 75. The distance between the contact pads 75 can be determined by the electrical contacts on the aerosol supply device 2.

[0137] Furthermore, in the described example, the heater assembly 6 is oriented such that the resistive layer 64 faces the bottom of the atomizing cartridge 3. However, the orientation of the heater assembly 6 is not limited to this, and in other implementations, the heater assembly 6 can be configured in an alternative orientation, for example, where the resistive layer faces away from the bottom of the atomizing cartridge 3.

[0138] It should also be understood that although the atomizing cartridge 3 including the heater assembly 6 has been described above, in some embodiments, the heater assembly 6 may be disposed within the aerosol supply device 2 itself. For example, the aerosol supply device 2 may include the heater assembly 6 and a removable cartridge (containing a reservoir of liquid aerosol generating material). The heater assembly 6 is configured to contact the liquid fluid in the cartridge (e.g., via a suitable wicking element or via an additional fluid delivery mechanism). Alternatively, in addition to the heater assembly 6, the aerosol supply device 2 may also include an integral liquid storage area that is refillable with liquid. More broadly, an aerosol supply system (which includes a separable aerosol supply device and an atomizing cartridge / cartridge or an integrated aerosol supply device and cartridge) includes a heater assembly.

[0139] Furthermore, the heater assembly 6 has already been described above, wherein a resistive layer 64 is disposed on the surface of the corresponding substrate. Figure 2 In the aerosol supply system 1, power is supplied to the resistive layer 64 via the contact pad 75. Thus, current can flow from one end of the resistive layer 64 to the other to cause heating of the resistive layer 64. However, it should be understood that the power used to cause heating of the resistive layer 64 can be provided by alternative means, and specifically, by induction heating. In this implementation, the aerosol supply system 1 is provided with a coil (called a drive coil) to which alternating current is applied. This subsequently generates an alternating magnetic field. When the resistive layer 64 is exposed to the alternating magnetic field (and it has sufficient strength), the alternating magnetic field induces currents (eddy currents) in the resistive layer 64. Due to the resistance of the resistive layer 64, these currents can cause Joule heating of the resistive layer 64. Depending on the material forming the resistive layer 64, additional heat can be generated by hysteresis if the material is ferromagnetic or ferrimagnetic. More generally, resistive layer 64 is an example of a heater layer of heater assembly 6, which is configured to generate heat when supplied with energy (e.g., electrical energy), which may be provided, for example, by direct contact or via induction. Other ways in which the heater layer generates heat are also considered within the principles of this disclosure.

[0140] Furthermore, it should be understood that in some implementations, one or more additional layers, such as a protective layer, may be disposed on top of the resistive layer 64. In this implementation, the capillary 66 still extends to the opening in the resistive layer 64, but may additionally extend through the additional one or more layers. More broadly, the capillary 66 extends through the heater assembly 6 to an opening on the surface of the heater assembly 6 that includes the resistive layer 64, including openings in the resistive layer 64 itself and openings in any additional layers above the resistive layer 64.

[0141] Figure 7 An exemplary method for manufacturing heater assembly 6 is described.

[0142] The method begins in step S1, providing a substrate 62. The manner in which the substrate 62 is formed is not important to the principles of this disclosure. For example, the substrate 62 can be cut from a portion of cultured quartz, or formed via a sintering process of sintering quartz powder / fiber.

[0143] The method then proceeds to step S2, where a resistive layer 64 is formed on the surface of the substrate 62. The manner in which the resistive layer 64 is formed on the surface of the substrate 62 is not important to the principles of this disclosure. For example, the resistive layer 64 may be a sheet of metal (e.g., titanium) adhered, welded, etc., to the substrate 62. Alternatively, the resistive layer 64 may be formed using the substrate 62 as a base via vapor phase or chemical deposition techniques.

[0144] It should also be understood that step S2 may alternatively occur before step S1. For example, another alternative is to use the resistive layer 64 as a base to grow or culture substrate 62.

[0145] In the described example, after step S2, the method proceeds to step S3. In step S3, one or more capillaries 66 are formed in the substrate 62 / resistive layer 64. As described above, the capillaries 66 extend from the surface of the substrate 62 / heater assembly 6 through the resistive layer 64 disposed on a first surface of the substrate 62. That is, the capillaries 66 extend all the way through the heater assembly 6. The capillaries 66 can be formed by laser drilling as described above or by any other suitable technique.

[0146] Furthermore, according to this disclosure, step S3 includes forming a first group of one or more capillaries 66a and forming a second group of one or more capillaries 66b. This may include drilling (or otherwise forming) capillaries 66a, 66b that have, for example, different sizes (diameters) or shapes. Alternatively or additionally, this may include applying a coating or performing a surface treatment as described above.

[0147] It should be understood that step S3 can be performed before step S2 (and similarly, step S3 can be performed after step S1, wherein step S2 is performed before step S1). That is, capillaries 66 can be formed in the substrate 62 before the resistive layer 64 is formed. In step S4, one or more surface-modified structures are provided to the heater assembly 6. As described above, surface-modified structures can be formed on at least a portion of one of the surface of the resistive layer 64, the second surface 62b of the substrate 62, and the sidewalls / surfaces of one or more capillaries 66. These surface-modified structures are formed to regulate the flow of aerosol-generating material capable of flowing along at least a portion of one of the surface of the resistive layer 64, the second surface 62b of the substrate 62, and the side surfaces of one or more capillaries 66. As described above, the surface-modified structures may include surface coatings and / or surface treatments, therefore, in step S4, any suitable technique can be used to provide the desired surface-modified structure, such as CVD or polishing.

[0148] In a broad sense, it should be understood that Figure 7 The method described herein is merely an exemplary method, and adaptations to the steps of the method or the order of the steps are contemplated within this disclosure, for example, as described above.

[0149] After step S3, heater assembly 6 is formed and can then be assembled to form atomizing cartridge 3 (or more generally, heater assembly 6 may be located in aerosol supply system 1).

[0150] According to the principles of this disclosure, an aerosol supply device is also provided, comprising an aerosol supply system 1. The aerosol supply device includes a heater device comprising a heater assembly 6. The heater device includes a substrate (including a substrate 62) and a heater layer device (including a resistive layer 64), the heater layer device being disposed on at least a first surface of the substrate and configured to generate heat. The heater device also includes a first set of capillary devices and a second set of capillary devices, the first set of capillary devices including a first set of capillaries 66a extending from a second surface of the substrate through the substrate and the heater layer device and having a first characteristic, and the second set of capillary devices including a second set of capillaries 66b extending from the second surface of the substrate through the substrate and the heater layer device and having a second characteristic different from the first characteristic. The aerosol supply device also includes an aerosol generating material storage device, the aerosol generating material storage device including a reservoir 44, the aerosol generating material storage device being in fluid communication with the second surface of the substrate. The aerosol generating material storage device also includes a first aerosol generating material and a second aerosol generating material. The second aerosol generating material has a higher viscosity than the first aerosol generating material. In addition, the first set of capillary devices is configured to impede the flow of the second aerosol-generating material.

[0151] Therefore, an aerosol supply system has been described, comprising a heater assembly and an aerosol generating material storage region. The heater assembly includes: a substrate; a heater layer disposed on at least a first surface of the substrate and configured to generate heat; a first set of one or more capillaries extending from a second surface of the substrate through the substrate and the heater layer and having a first characteristic; and a second set of one or more capillaries extending from the second surface of the substrate through the substrate and the heater layer and having a second characteristic different from the first characteristic. The aerosol generating material storage region is in fluid communication with the second surface of the substrate and includes a first aerosol generating material and a second aerosol generating material. The second aerosol generating material has a higher viscosity than the first aerosol generating material, and the first set of one or more capillaries is configured to impede the flow of the second aerosol generating material. Consumables for use with the aerosol supply system, methods of manufacturing the aerosol supply system, or a consumable and aerosol supply device are also described.

[0152] Alternatively, this disclosure can be summarized as an aerosol supply system including a heater assembly. The heater assembly includes a substrate; a heater layer disposed on at least a first surface of the substrate and configured to generate heat; a first set of one or more capillaries extending from a second surface of the substrate through the substrate and reaching the heater layer and having a first characteristic; and a second set of one or more capillaries extending from the second surface of the substrate through the substrate and reaching the heater layer and having a second characteristic different from the first characteristic. The aerosol supply system further includes an aerosol generating material storage region in fluid communication with the second surface of the substrate, the aerosol generating material storage region including a first aerosol generating material and a second aerosol generating material. The second aerosol generating material has a higher viscosity than the first aerosol generating material. The first set of one or more capillaries is configured to impede the flow of the second aerosol generating material.

[0153] According to another aspect of this disclosure, a heater assembly is provided, comprising a surface-modified structure (including a surface coating and / or surface treatment) configured to adjust the flow of an aerosol-generating material capable of flowing along at least a portion of the heater assembly. Specifically, this adjustment is made along one or more of the following: a surface of a heater layer, a surface of a substrate facing an aerosol-generating material storage area, and a side surface of one or more capillaries extending between a second surface and the heater layer. By providing the surface-modified structure, characteristics of the heater assembly with respect to liquid flow or delivery can be altered or adjusted. This allows designers of the heater assembly greater freedom in terms of materials that can be used to produce the assembly, as the surface-modified structure can be used to fine-tune the performance of the heater assembly even when the bulk material used to produce the heater assembly does not possess the desired properties with respect to liquid flow.

[0154] refer to Figure 3 According to another aspect of this disclosure, capillary 66 is configured to deliver liquid from one surface of heater assembly 6 (i.e., the second surface 62b of substrate 62) to resistive layer 64. Capillary 66 may be formed in part based on the liquid to be stored in reservoir 46 of atomizing cartridge 3 and subsequently used with heater assembly 6. For example, the properties (e.g., viscosity) of the liquid aerosol-generating material in reservoir 46 of atomizing cartridge 3 can influence the configuration of capillary 66 to help ensure a suitable liquid flow to resistive layer 64. Generally, in some implementations, capillary 66 may have a diameter of approximately tens of micrometers, for example, between 10 µm and 100 µm. However, it should be understood that in other implementations, capillary 66 may be configured differently.

[0155] According to another aspect of this disclosure, the heater assembly 6 is configured to facilitate the transport of liquid aerosol generating material from the reservoir 46 to the resistive layer 64, such that the liquid aerosol generating material can be vaporized to form an aerosol. The liquid aerosol generating material can contact the heater assembly 6 at several locations. Specifically, the liquid aerosol generating material can contact the second surface 62b of the substrate 62 (facing the reservoir 64 when the heater assembly is clamped between the upper clamping unit 5 and the lower support unit 7), the surface of the capillary 66, and the exposed surface 64a of the resistive layer 64 (e.g., when liquid escapes from the end of the capillary 66 in liquid form or due to condensation on the exposed surface 64a of the resistive layer 64 after vaporization). Therefore, it should be understood that the liquid aerosol generating material can flow along any one or more of these surfaces.

[0156] When a liquid interacts with a surface, the contact angle is a parameter that determines the extent to which a droplet will spread across the surface. A relatively large contact angle means that the liquid is less likely to spread on the surface, while a smaller contact angle means that the liquid is more likely to spread on the surface. The contact angle depends in part on the properties of the materials forming the surface. Generally, the properties of surfaces can be found in their surface energy. For a given liquid, a surface with higher surface energy allows for greater diffusion of the liquid on the surface, while a surface with lower surface energy allows for less diffusion of the liquid on the surface.

[0157] When considering the heating assembly 6 of the present invention, it should be understood that liquid is supplied to the resistive layer 64 via capillary 66 and potentially via the second surface 62b. The liquid in contact with these surfaces has a certain contact angle and therefore a degree of diffusion associated with the respective surfaces. The liquid flow characteristics of the surfaces can also be set or altered by changing or setting the contact angle of a given liquid relative to the aforementioned surfaces. For example, in some cases, it may be desirable to promote the flow of liquid along the second surface 62b and / or along the capillary channel 66, thereby increasing the rate at which liquid is supplied to the resistive layer 64. In some cases, it may be desirable to reduce the flow of liquid along the second surface 62b and / or along the capillary 66, thereby reducing the set rate of liquid to the resistive layer 64.

[0158] Similarly, the liquid contacting the resistive layer 64 also forms a specific contact angle with the surface of the resistive layer 64. In this case, the surface area of ​​the liquid supplying the resistive layer 64 from the capillary 66 can be partially controlled by the contact angle formed between the liquid and the surface of the resistive layer 64 during the heating / evaporation of the liquid. By changing or setting the contact angle of a given liquid relative to the surface of the resistive layer 64, the liquid flow characteristics of the surface of the resistive layer 64 can also be set or changed. For example, the degree of diffusion of droplets on the resistive layer 64 (and therefore the surface area of ​​the droplets contacting the resistive layer 64) can be increased or decreased based on the properties of the surface of the resistive layer 64. This can subsequently affect the rate or amount of aerosol generated during vaporization. Furthermore, condensed liquid (i.e., liquid that has evaporated and subsequently condenses in the area below the heater assembly 6) can also be collected on the surface of the resistive layer 64. This liquid can also form a contact angle with the surface of the resistive layer 64 (which may be the same as or different from the contact angle of the pre-evaporated liquid). By changing or setting the contact angle of a given liquid relative to the surface of the resistive layer 64, the liquid flow characteristics of the surface of the resistive layer 64 can also be set or changed. For example, in some cases, it may be desirable to set the flow of condensed liquid along the resistive layer 64, thereby setting the rate at which the liquid is fed at the resistive layer 64 to the capillary 66 (or its opening).

[0159] Therefore, more generally, it should be understood that the contact angle formed between the liquid and the corresponding surface of the heater assembly 6 can affect the liquid flow characteristics of the corresponding surface of the heater assembly 6.

[0160] According to another aspect of the principles of this disclosure, the heater assembly 6 includes a surface-modified structure configured to adjust (i.e., set or change) the flow of aerosol-generating material capable of flowing through the substrate 62 along at least a portion of one or more of the surfaces of the resistive layer 64 (or more generally, the heater layer), the second surface 62b of the substrate 62, and the side surfaces of one or more capillaries 66. By providing the surface-modified structure at at least a portion of one or more of the surfaces of the resistive layer 64, the second surface 62b of the substrate 62, and the side surfaces of one or more capillaries 66 through the substrate 62, the liquid flow characteristics of liquids contacting any of the aforementioned surfaces can be altered relative to surfaces without the surface-modified structure. In some implementations, the surface-modified structure may be provided to increase (i.e., enhance) the rate of liquid flow along the respective surface relative to surfaces or portions of surfaces without the surface-modified structure. This can help increase the amount and / or rate of aerosols generated during vaporization. Additionally or alternatively, surface-modified structures may be provided to impede (i.e., reduce) the rate of liquid flow along the respective surface relative to surfaces without surface-modified structures or portions of the surface. This can help reduce the amount of aerosols generated during vaporization and / or the rate at which aerosols are generated during vaporization.

[0161] The surface modification structure can be any suitable modification to the surface of the underlying bulk material (e.g., substrate 62 and / or resistive layer 64) that alters the surface properties (e.g., surface energy) in the region where the surface modification structure is disposed.

[0162] In some implementations, the surface-modified structure includes a surface coating. For example, a surface coating of another material can be applied to the surface of the substrate 62 and / or the resistive layer. Depending on the properties of the applied material and / or the manner of application, the surface coating can increase or decrease certain properties of the underlying bulk material to which the coating is applied. In particular, the surface coating can increase or decrease the surface energy of the underlying bulk material.

[0163] In some implementations, a surface coating can be applied using plasma processing (e.g., in the fabrication of silicon wafers). In such implementations, the underlying substrate 62 and / or resistive layer 64 can be bombarded with ions to modulate the surface energy of the underlying material, for example, to make the surface more hydrophobic or more hydrophilic as needed. A mixture of inert gases (e.g., krypton or argon) can be used to form the plasma, but other gases may also be used. The gas mixture can be selected to impart certain properties to the surface of the underlying material. In other implementations, spin coating can be used to apply an organic surface coating to the underlying material (e.g., substrate 62 and / or resistive layer 64). The coating or film applied by spin coating can be several nanometers or micrometers thick, which may be suitable for certain applications.

[0164] Any suitable material can be applied as a surface coating to heater assembly 6. However, it should be understood that the properties of the surface coating material can differ when applied to different parts of heater assembly 6. For example, since resistive layer 64 is intended to receive current and generate heat during operation, the surface coating applied to the surface of resistive layer 64 can be selected to be non-conductive and / or heat-resistant (up to the common operating temperature of resistive layer 64). Furthermore, any suitable technique for applying the surface coating to heater assembly 6 can be used. For example, techniques such as chemical vapor deposition (CVD) can be used to deposit suitable materials on the surface of heater assembly 6 using widely conventional techniques.

[0165] In other implementations, the surface modification structure includes surface treatment. Surface treatment is any treatment performed on the corresponding surface of the heater assembly 6 (e.g., substrate 62 and / or resistive layer 64) that subsequently alters the surface properties (such as surface energy) of the bulk material. For example, surface treatment may include etching, grinding, scoring, or any other similar treatment that roughens the surface. In other examples, surface treatment may include polishing or otherwise smoothing the surface of the heater assembly 6. In some implementations, laser ablation may be used to provide roughness to the surface of the underlying material or remove rough or uneven areas (depending on the state of the underlying material prior to treatment). In other implementations, UV ozone treatment may be used to treat the surface of the underlying substrate 62 and / or resistive layer 64, thereby providing temporary cleaning of the surface (thereby removing any contaminants or the like that may otherwise affect the surface energy of the material). Furthermore, a wide range of conventional techniques may be used to perform surface treatment on the corresponding surface of the heater assembly 6.

[0166] In some implementations, the surface modification structure is provided on the entire corresponding surface of the heater assembly 6. That is, the surface modification structure can be provided on the entire second surface 62b of the substrate and / or on the entire sidewall of the capillary 66 and / or on the entire resistive layer 64. This can be achieved when the bulk material of the substrate 62, the capillary 66, and / or the resistive layer 64 exhibit unsuitable properties with respect to liquid flow (but may exhibit desired qualities with respect to other properties such as thermal conductivity / insulation, resistivity, etc.). In other implementations, the surface modification structure can be provided only on a portion of the corresponding surface of the heater assembly 6. That is, the surface modification structure can be provided on a portion of the second surface 62b of the substrate and / or a portion of the sidewall of the capillary 66 and / or a portion of the resistive layer 64. By providing the surface modification structure on only a portion of the corresponding surface, multiple portions can be provided on the corresponding surface, in which the flow of aerosol-generating material can be facilitated / impeded relative to other portions of the corresponding surface. For example, the surface modification structure can be provided to facilitate the flow of aerosol-generating material to specific areas of the heater assembly 6. That is, the target area of ​​heater assembly 6 can have areas that increase (or decrease) liquid flow characteristics, such that those areas can receive increased (or decreased) amounts of liquid aerosol generating material.

[0167] Furthermore, in implementations with multiple capillaries 66, it is not necessary to provide a surface modification structure for each capillary 66. That is, for example, the sidewalls (or portions thereof) of some of the multiple capillaries 66 may have a surface modification structure, while other capillaries 66 may not have a surface modification structure (or the sidewalls or portions thereof may have different surface modification structures). This allows for selective adjustment of the liquid flow characteristics of some of the multiple capillaries 66. For example, the liquid flow characteristics of capillaries 66 towards the center of the heater assembly can be relatively improved, while the liquid flow characteristics of capillaries 66 towards the periphery of the heater assembly 6 can be relatively reduced. Certain factors may exist to determine which capillaries 66 to which surface features are applied (e.g., the operating temperature of the resistive layer 64 near the ends / openings of the capillaries 66, etc.).

[0168] As described above, in some implementations, the surface-modified structure is configured to facilitate the flow of aerosol-generating materials capable of flowing along at least one of the surfaces of the resistive layer 64, the second surface 62b of the substrate 62, and the side surfaces of one or more capillaries 66. For example, by applying a surface coating or performing a surface treatment, the surface energy of the surface can be relatively increased compared to the layer bulk material. For a given liquid, this results in a relatively small contact angle and thus allows for greater droplet diffusion on the surface. Such a surface can be said to have high wettability. Such a surface can be considered to facilitate or enable greater liquid transport compared to a surface without such a surface-modified structure. Furthermore, depending on the type of liquid to be used with the heater assembly 6, the surface-modified structure can be considered to have different qualities. In implementations where the liquid is water or water-based, the surface-modified structure can be considered to make the surface relatively more hydrophilic. In implementations where the liquid is oil or oil-based, the surface-modified structure can be considered to make the surface relatively more oleophilic. In this regard, it should be understood that the surface energy of the material is not the only factor determining the liquid contact angle. In fact, the contact angle also depends at least on the surface tension of a given droplet (i.e., the inherent properties of the liquid). Therefore, it should be understood in the text of this disclosure that specific surface modifications can be applied to the heater assembly 6 in consideration of the liquid (or multiple liquids) with which it will be used. Thus, it should be understood that a given surface modification structure can have different effects on different liquids, and the degree to which the surface needs to be modified can depend on the liquid to be used with the heater assembly 6.

[0169] In some other implementations, the surface-modified structure is configured to impede the flow of aerosol-generating material capable of flowing along at least one of the surfaces of the resistive layer 64, the second surface 62b of the substrate 62, and the side surfaces of one or more capillaries 66. For example, by applying a surface coating or performing a surface treatment, the surface energy of the surface can be relatively reduced compared to the underlying bulk material. For a given liquid, this results in a relatively large contact angle and thus less droplet diffusion on the surface. Such a surface can be described as having low wettability (sometimes referred to as "dewetting"). Such a surface can be considered to impede the transport of liquid across the surface to a greater extent than a surface without such a surface-modified structure. Furthermore, depending on the type of liquid to be used with the heater assembly 6, the surface-modified structure can be considered to have different qualities. In implementations where the liquid is water or water-based, the surface-modified structure can be considered to make the surface relatively more hydrophobic. In implementations where the liquid is oil or oil-based, the surface-modified structure can be considered to make the surface relatively more oleophobic. As mentioned above, it should be understood that the surface energy of a material is not the only factor determining the contact angle of a liquid (and this can depend on the liquid to be used with heater assembly 6).

[0170] Therefore, by utilizing the surface modification structures described above, heater assembly 6 can be modified or adjusted to provide certain characteristics in terms of the performance of the liquid flow to certain portions of heater assembly 6. This provides the designer of heater assembly 6 with greater freedom to select certain bulk materials with certain specific performance characteristics, even if these bulk materials are unsatisfactory in other (i.e., liquid flow) performance characteristics. Furthermore, surface modification structures can be provided at certain locations in heater assembly 6 to provide more selective liquid flow / delivery to those locations. This can be used to fine-tune the performance of heater assembly 6. For example, in terms of aerosol generation, surface modification structures can be provided to supply relatively more liquid (or supply liquid at a higher rate) to the center of heater assembly 6, which may be a more suitable location for aerosol generation conditions compared to, for example, the edges of heater assembly 6.

[0171] Figure 8a and Figure 8b A first implementation of a heater assembly 6, including a surface-modified structure according to another aspect of this disclosure, is illustrated schematically. Specifically, Figure 8a and Figure 8b A heater assembly 6 having a surface-modified structure disposed on a second surface 62b of a substrate 62 is schematically shown. Figure 8a A top view of the second surface 62b of the base 62 is shown, while Figure 8b A perspective view of heater assembly 6 is shown. Figure 3 compared to, Figure 8b The heater assembly 6 is shown rotated 180° about the longitudinal axis L2 to allow observation of the second surface 62b. (Note that...) Figure 8b This shows that heater assembly 6 will be in the position during assembly. Figure 2 (The directional heater assembly 6 in the atomizing cartridge 3.)

[0172] As should be understood, the second surface 62b of the substrate 62 faces the reservoir 46 and is therefore configured to at least partially contact the liquid aerosol generating material within the reservoir 46. Liquid exiting the reservoir 46 contacts the second surface 62b of the heater assembly 6 at a first point of contact with the heater assembly 6.

[0173] exist Figure 1 and Figure 2In the arrangement of the atomizing cartridge 3 described herein, the heater assembly 6 is configured such that its ends 68, 69 overlap with the opening of the groove 53 in the upper clamping unit 5. In some implementations, a wicking material may be provided between the opening of the groove 53 and the second surface 62b, which can facilitate the delivery of liquid in the direction along the second surface 62b (i.e., approximately along the longitudinal direction L2 of the heater assembly 6). However, regardless of whether a wicking material is provided, it is anticipated that at least some of the liquid from the reservoir 46 will be delivered to the portion of the second surface 62b at the ends 68, 69 of the heater assembly 6 that overlaps with the opening leading to the groove 53. Since the ends 68, 69 do not have any capillaries 66 and are not in communication with the central air passage 73, it is desirable to guide the liquid toward the central portion 67 when the capillaries 66 are positioned, and thus ultimately deliver the liquid to the resistive layer 64.

[0174] According to the first example, the heater assembly 6 (and more specifically, the second surface 62b of the substrate 62) has a first surface modification structure 191 at each end 68, 69 of the second surface 62b of the substrate 62. The first surface modification structure 191 is provided to relatively increase the surface energy of the bulk material (i.e., the substrate 62) at the portion where the first surface modification structure 191 is provided, compared to the portion of the second surface 62b without the first surface modification structure 191. For the liquid itself, this results in a relatively small contact angle with the surface 62b in the region having the first surface modification structure 191, thus allowing the liquid to experience greater diffusion on the surface 62b. Therefore, the first surface modification structure 191 is provided to increase or improve the liquid flow characteristics of the second surface 62b in the region where the first surface modification structure 191 is provided. In particular, the first surface modification structure 191 can facilitate liquid flow toward the capillaries 66 adjacent to the first surface modification structure 191. In this respect, from Figure 8a and Figure 8b As can be seen, the first surface modification structure 191 is configured to have a generally truncated conical shape, wherein the narrower portion of the truncated conical shape faces the capillary 66 of the central portion 67 of the heater assembly 6. Therefore, due to the first surface modification structure 191, liquid leaving the groove 53 can flow to the capillary 66, and thus to the resistive layer 64.

[0175] Furthermore, it should be understood that capillary 66 is the primary path through which liquid is supplied to resistive layer 64. That is, in order for the liquid aerosol generating material to be transferred to resistive layer 64, it primarily passes through capillary 66. One way to facilitate the flow of liquid to resistive layer 64 is to facilitate the flow of liquid to capillary 66.

[0176] Therefore, in Figure 8a and Figure 8bIn the described implementation, the second surface 62b is provided with a plurality of second surface modification structures 92. The second surface modification structures 92 are disposed on the second surface 62b at positions around the opening of the capillary 66. Figure 8a and Figure 8b In the example, the opening of capillary 66 is circular, and therefore the second surface modification structure 92 is also circular (albeit with a larger diameter) and coaxial with the opening of capillary 66. Similar to the first surface modification structure 191, the second surface modification structure 92 is configured to provide a relatively increased surface energy of the bulk material (i.e., substrate 62) at the portion of the second surface 62b where the second surface modification structure 92 is provided, compared to the portion of the second surface 62b without the first surface modification structure 191 or the second surface modification structure 92. As for the liquid itself, this again results in a relatively small contact angle with surface 62b in the region having the second surface modification structure 92, thus allowing the liquid to experience greater diffusion on surface 62b. Therefore, the second surface modification structure 92 is provided to increase or improve the liquid flow characteristics of the second surface 62b in the region where the second surface modification structure 92 is provided. In particular, the second surface modification structure 92 is capable of promoting liquid flow to the opening of capillary 66. Therefore, due to the second surface modification structure 92, the liquid near the opening of the capillary 66 can flow more easily or more readily to the opening of the capillary 66 and thus to the resistive layer 64.

[0177] Therefore, it can be seen that the first surface modification structure 191 and the second surface modification structure 92 are configured to promote the flow of aerosol generating material that can flow along the second surface 62b of the substrate 62, making it easier or more readily possible for the aerosol generating material to flow toward the capillary 66 (or more specifically, the opening of the capillary 66).

[0178] also, Figure 8a and Figure 8b The heater assembly 6 is provided with a third surface modification structure 93. Unlike the first surface modification structure 191 and the second surface modification structure 92, the third surface modification structure 93 is configured to relatively reduce the surface energy of the bulk material (i.e., the substrate 62) at the portion of the second surface 62b where the third surface modification structure 93 is provided, compared to the portions where the first surface modification structure 191 and the second surface modification structure 92 are not provided. For the liquid itself, this results in a relatively large contact angle with the surface 62b in the region having the third surface modification structure 93, thus the liquid experiences relatively less diffusion on the surface 62b. Therefore, the third surface modification structure 93 is provided to suppress or reduce the liquid flow characteristics in the region of the second surface 62b where the third surface modification structure 93 is provided.

[0179] The third surface modification structure 93 is disposed at the center of the central portion 67 on the edge of the second surface 62b. More specifically, the third surface modification structure 93 is disposed between the edge of the second surface 62b (and therefore the edge of the heating assembly 6) and the capillary 66. The third surface modification structure 93 acts as a barrier to the flow of liquid toward the edge of the second surface 62b (and therefore to the flow of liquid away from the capillary 66). Thus, the third surface modification structure can be considered as a barrier that retains liquid that has reached the center of the central portion 67 in this region, which can thus increase the chance of liquid reaching the capillary 66. Therefore, due to the third surface modification structure 93, liquid that has reached the center of the central portion 67 can be retained or held in this region, making it easier to supply to the capillary 66.

[0180] Therefore, according to Figure 8a and Figure 8b In a first example, the second surface 62b of the substrate 62 of the heater assembly 6 is provided with one or more surface modification structures 191, 92, 93, which are arranged to alter the flow of the liquid aerosol generating material across the surface of the second surface 62b. In the described example, the first surface modification structure 191 and the second surface modification structure 92 are provided to relatively promote the flow of the liquid aerosol generating material across the second surface 62b, thereby promoting a relative increase in the amount and / or rate of aerosol generating material supplied to certain portions of the second surface 62b (i.e., toward the capillary 66), while the third surface modification structure 93 is configured to relatively reduce the flow of the liquid aerosol generating material across the second surface 62b, thereby relatively reducing the amount and / or rate of aerosol generating material supplied to certain portions of the second surface 62b (i.e., away from the capillary 66). However, it should be understood that... Figure 8a and Figure 8b The implementation shown is merely an example, and in other implementations, the settings of surface modification structures 191, 92, and 93 may differ from those shown.

[0181] For example, in some implementations, it may be desirable to switch the relative increase and decrease of the surface energy of the second surface 62b provided by the first surface-modified structure to the third surface-modified structures 191, 92, 93. That is, the first surface-modified structure 191 and the second surface-modified structure 92 may alternatively be configured to relatively reduce the surface energy compared to the portion of the second surface 62b without the surface-modified structure, while the third surface-modified structure 93 may alternatively be configured to relatively increase the surface energy compared to the portion of the second surface 62b without the surface-modified structure. This can be achieved if the flow of liquid aerosol generating material across the second surface 62b is too large (i.e., the supply amount and / or rate of the aerosol generating material is too high for the heater assembly, resulting in overflow and / or poor vaporization at the resistive layer 64). Therefore, the first surface-modified structure 191 and the second surface-modified structure 92 can be provided to effectively slow down the supply of aerosol generating material to the capillary 66. In other words, the first and second surface-modified structures are configured to impede the flow of aerosol-generating material that can flow along the second surface 62b of the substrate 62, thereby reducing the flow of aerosol-generating material toward the openings of one or more capillaries 66. Similarly, a third surface-modified structure 93 can be provided to promote the flow of aerosol-generating material away from the capillaries 66, thereby reducing the amount of liquid aerosol-generating material that accumulates or collects in the central region 67 of the second surface 62b.

[0182] Therefore, it should be understood that surface modification structures 191, 92, 93 can be provided to the second surface 62b of the heater assembly 6 to influence the flow or transport of the liquid aerosol generating material across the second surface 62b. Depending on the specific characteristics of the heater assembly 6 and its interaction with the liquid aerosol generating material, the surface modification structures 191, 92, 93 can be configured in any desired manner to achieve specific results. Although Figure 8a and Figure 8b Examples show surface modification structures for increasing surface energy (i.e., the first surface modification structure 191 and the second surface modification structure 92) and surface modification structures for decreasing surface energy (i.e., the third surface modification structure 93), but it should be understood that some implementations may employ only one type of surface modification structure. Additionally, although Figure 8a and Figure 8b Specific shapes and distributions of surface modification structures 191, 92, and 93 are shown, but it should be understood that these are merely examples, and other implementations may include surface modification structures with different shapes and / or different distributions spanning the second surface 62b. Furthermore, as mentioned above, in some implementations, the surface modification structure may be provided across the entire surface 62b.

[0183] Figure 9a and Figure 9bA second and a third implementation of the heater assembly 6, including a surface-modified structure, according to another aspect of this disclosure are schematically shown. Specifically, Figure 9a and Figure 9b The heater assembly 6 is schematically shown, having a surface-modified structure disposed on the sidewall of the capillary 66. The capillary 66 is formed in the substrate 62, and therefore it should be understood that the sidewall of the capillary 66 is also the sidewall of the substrate 62. Figure 9a and Figure 9b A cross-sectional view through heater assembly 6 is shown, and an example capillary 66 is shown to illustrate the principles of this disclosure.

[0184] Regarding capillary 66, as described above, it should be understood that capillary 66 is the primary mechanism through which its liquid aerosol generating material is supplied to resistive layer 64 for vaporization. The extent to which the liquid aerosol generating material travels through capillary 66 can depend on many factors, such as the geometry of capillary 66 (e.g., the radius of capillary 66) and the properties of the liquid aerosol generating material (e.g., surface tension). Another factor is the contact angle of the droplets (or menisci) formed with the sidewalls of capillary 66. In a manner substantially similar to that described above, the contact angle or surface energy of the sidewalls of capillary 66 can be adjusted using surface modification structures on the sidewalls of capillary 66. By adjusting the contact angle or surface energy, the flow of liquid aerosol generating material capable of flowing along at least a portion of the sidewalls of one or more capillary 66 can also be regulated.

[0185] Figure 9a A second implementation is shown, wherein the sidewall of the capillary 66 is provided with a fourth surface modification structure 94. The fourth surface modification structure 94 is similar to the first surface modification structure 191 and the second surface modification structure 92 described above in that, compared to the portions of the sidewall of the capillary 66 without the fourth surface modification structure 94, the portions with the fourth surface modification structure 94 provide a relatively increased surface energy of the bulk material (i.e., the substrate 62). Similarly, with regard to the liquid aerosol generating material itself, this results in a relatively small contact angle with the sidewall of the capillary 66 in the region having the fourth surface modification structure 94. In the case of a capillary 66 where the liquid aerosol generating material is more constrained, this effectively means that the liquid aerosol generating material travels relatively further along the capillary 66, or actually travels at a faster rate than in the case without the fourth surface modification structure 94. Therefore, a fourth surface modification structure 94 is provided to increase or improve the flow characteristics of the liquid in the portion of the capillary 66 in which the fourth surface modification structure 94 is provided.

[0186] exist Figure 9aIn this implementation, the fourth surface modification structure 94 is disposed on the portion of the capillary 66 adjacent to the opening in the second surface 62b. In other words, the fourth surface modification structure 94 is disposed at the portion of the capillary 66 that first receives the liquid aerosol generating material. In this regard, the fourth surface modification structure 94 can help facilitate a faster loading of the liquid aerosol generating material into the capillary 66. This can help improve the supply of the liquid aerosol generating material to the resistive layer 64 during and before the use of the heating assembly 6. Figure 9a In the example, the fourth surface modification structure 94 does not extend to the resistive layer 64 (i.e., the entire length of the capillary 66). In this regard, it should be understood that in some implementations, the relative pressure exerted by the liquid present in the region of the capillary 66 including the fourth surface modification structure 94 on the volume of liquid in the region of the capillary 66 excluding the fourth surface modification structure 94 (i.e., closest to the resistive layer 64) can affect the liquid flow properties in the region closest to the resistive layer 64. In other words, the additional pressure can force the liquid closest to the resistive layer 64 to flow more easily and / or at a greater rate, even without the fourth surface modification structure 94. Furthermore, during use, residual heat from the resistive layer 64 can heat the volume of liquid in the region of the capillary 66 excluding the fourth surface modification structure 94 (i.e., closest to the resistive layer 64) to a greater extent than the liquid held in the region including the fourth surface modification structure 94. In this case, the properties (e.g., viscosity) of the liquid closest to the resistive layer 64 can be altered, making it easier and / or at a greater rate of flow, even without the fourth surface modification structure 94. Simply put, it is not necessary to include the fourth surface modification structure 94 along the entire length of the capillary 66, as other factors can affect the flow of liquid through the capillary 66 at different portions of the capillary 66. However, it should also be understood that in other implementations, the fourth surface modification structure 94 can be provided along the entire length of the capillary 66, particularly where the aforementioned factors are negligible.

[0187] according to Figure 9a The second implementation provides a fourth surface modification structure 94 to help facilitate the supply of liquid to the resistance layer 64 (i.e., to help prevent or reduce dry-running of the resistance layer 64, i.e., insufficient supply of liquid).

[0188] Figure 9bA third implementation of a fifth surface modification structure 95 on the sidewall of capillary 66 is shown. Similar to the third surface modification structure 93 described above, the fifth surface modification structure 95 provides a relatively lower surface energy of the bulk material (i.e., substrate 62) at the portion of the capillary 66 where the fifth surface modification structure 95 is provided, compared to the portions of the capillary 66 without the fifth surface modification structure 95. Similarly, with regard to the liquid aerosol generating material itself, this results in a relatively large contact angle with the sidewall of capillary 66 in the region having the fifth surface modification structure 95. In the case of a capillary 66 where the liquid aerosol generating material is more constrained, this effectively means that the liquid aerosol generating material travels a relatively shorter distance along the capillary 66, or travels at a slower rate than in the case without the fifth surface modification structure 95. Therefore, the fifth surface modification structure 95 is provided to reduce or impede the liquid flow characteristics of the capillary 66 in the portion where the fifth surface modification structure 95 is provided.

[0189] exist Figure 9b In one implementation, the fifth surface modification structure 95 is disposed on the portion of the capillary 66 adjacent to the opening in the resistive layer 64. In other words, the fifth surface modification structure 95 is disposed at the portion of the capillary 66 directly adjacent to the resistive layer 64, and liquid material is subsequently supplied to the resistive layer 64. As described above, effects such as the relative pressure applied to the liquid volume near the resistive layer 64 and / or residual heat from the resistive layer 64 can relatively increase the flow of the liquid aerosol generating material in the region near the resistive layer 64. This can lead to effects such as leakage of the liquid aerosol generating material (e.g., into the central air passage 73) and / or overflow of the resistive layer 64. Therefore, in some implementations, providing the fifth surface modification structure 95 and facilitating the retention of at least some of the liquid aerosol generating material in the capillary 66 (at least when the heater assembly 6 is not operating) helps to reduce or prevent leakage of the liquid aerosol generating material. Figure 9b In the diagram, the fifth surface modification structure 95 is shown disposed at the portion of the sidewall of the capillary 66 closest to the resistive layer 64, partly because this is where the effects of any residual temperature and pressure are considered greatest. However, it should also be understood that in other implementations, the fifth surface modification structure 95 can be disposed along the entire length of the capillary 66, particularly where the aforementioned factors are negligible and liquid aerosol generation can flow too freely along the entire length of the capillary 66.

[0190] according to Figure 9b The third implementation provides a fifth surface modification structure 95 to help slow down the supply of liquid to the resistive layer 64 (i.e., to help prevent or reduce the leakage of liquid aerosol generating material from the resistive layer 64).

[0191] although Figure 9a and Figure 9b The arrangement shown illustrates a fourth surface modification structure 94 and a fifth surface modification structure 95 disposed in certain portions of the capillary 66; however, it should be understood that in some implementations, the functions of the fourth surface modification structure 94 and the fifth surface modification structure 95 may be reversed. For example, regarding... Figure 9a In some implementations of the arrangement, it can be found that the liquid aerosol generating material passes through the second surface 62b / reservoir 46 at a rate greater than desired, and therefore the fourth surface modification structure 94 can alternatively be configured to relatively reduce the surface energy of the sidewalls of the capillary 66 in the region closest to the second surface 62b, and subsequently not be present in the region closest to the resistive layer 64, so as not to restrict the flow of liquid to the resistive layer 64 during vaporization. Alternatively, regarding Figure 9b In this arrangement, the fifth surface modification structure 95 can alternatively be arranged to relatively increase the surface energy of the sidewalls of the capillary 66 in the region closest to the resistive layer 64, in order to help improve the flow of liquid to the resistive layer 64 during evaporation.

[0192] More generally, it should be understood that surface modification structures (i.e., a fourth surface modification structure 94 or a fifth surface modification structure 95) are provided on at least a portion of the side surfaces of one or more capillaries 66 to regulate the characteristics of at least a portion of the side surfaces of one or more capillaries 66 relative to the flow of aerosol-generating material capable of flowing along the side surfaces of one or more capillaries 66. In some implementations, the surface modification structures may be configured to promote the flow of aerosol-generating material, allowing the aerosol-generating material to flow through one or more capillaries 66 at a greater rate. This ensures that the resistive layer 64 is supplied with sufficient aerosol-generating material and reduces or avoids dry-running of the resistive layer 64. In some implementations, the surface modification structures may be configured to impede the flow of aerosol-generating material, allowing the aerosol-generating material to flow through one or more capillaries 66 at a lower rate. This helps to retain liquid within the capillary 66 / heater assembly 6 and avoids, for example, leakage. In general, it should be understood that providing the fourth surface modification structure 94 and the fifth surface modification structure 95 allows the performance of the heater assembly 6 to be modified or adjusted as desired in order to provide a certain performance or certain characteristics.

[0193] As described above, it should also be understood that all capillaries of the plurality of capillaries 66 may include the same surface-modified structure, or in other implementations, only some of the capillaries of the plurality of capillaries 66 may be provided with a surface-modified structure, or alternatively, different surface-modified structures may be applied to different capillaries 66. This allows for more selective or targeted control of the liquid flow characteristics in certain regions of the heater assembly 6. For example, it may be desirable to relatively increase the flow of liquid to regions of the heater assembly 6 with higher operating temperatures (e.g., the center of the central portion 67), because the vaporization rate may be highest in these regions.

[0194] Figure 10a and Figure 10b A fourth implementation of a heater assembly 6 including a surface-modified structure according to another aspect of this disclosure is schematically shown. Specifically, Figure 10a and Figure 10b A heater assembly 6 having a surface-modified structure disposed on the surface of a resistive layer 64 is schematically shown. Figure 10a A top view of the surface of resistor layer 64 is shown, while Figure 10b A perspective view of heater assembly 6 is shown.

[0195] As should be understood, the surface of the resistive layer 64 faces the central air channel 73 and is therefore arranged to receive liquid from the capillary 66 and cause the liquid to evaporate to form vapor, which is provided at least initially in the vicinity of the central air channel 73.

[0196] According to the fourth implementation, a sixth surface modification structure 96 is provided on the surface of the heater assembly 6 (and more specifically, the surface of the resistive layer 64), which is located around the opening of the capillary 66 on the surface of the resistive layer 64. In principle, the sixth surface modification structure 96 is similar to... Figure 8a and Figure 8b The second surface modification structure 92. In a manner similar to the second surface modification structure 92, the sixth surface modification structure 96 is configured to relatively increase the surface energy of the bulk material (i.e., the resistive layer 64) at the portion where the sixth surface modification structure 92 is provided, compared to those portions of the surface of the resistive layer 64 where the sixth surface modification structure 96 is not provided.

[0197] Similarly, with respect to the liquid itself, this results in a relatively small contact angle with the surface of the resistive layer 64 in the portion having the sixth surface modification structure 96, and thus the liquid experiences greater diffusion on the surface of the resistive layer 64 (especially near the opening of the capillary 66). Therefore, the sixth surface modification structure 96 is provided to increase or improve the liquid flow characteristics on the surface of the resistive layer 64 in the portion where the sixth surface modification structure 96 is provided. In particular, the sixth surface modification structure 96 enables the liquid aerosol generating material supplied by the capillary 66 to be dispersed over a larger area of ​​the surface of the resistive layer 64. Since the resistive layer 64 is responsible for evaporating the liquid to form an aerosol during the use of the heater assembly 6, increasing the effective surface area of ​​the resistive layer 64 in contact with the liquid means that the resistive layer 64 can help evaporate the same relative amount of liquid more quickly. In other words, by dispersing the liquid aerosol generating material on the surface of the resistive layer 64, the heater assembly 6 is able to evaporate the liquid at a relatively faster rate. Therefore, due to the sixth surface modification structure 96, the liquid near the opening of the capillary 66 can flow more easily or more readily across the surface of the resistive layer 64, and is therefore more easily evaporated by the resistive layer 64.

[0198] also, Figure 10a and Figure 10b The heater assembly 6 has a seventh surface modification structure 97. The seventh surface modification structure 97 is configured to relatively reduce the surface energy of the bulk material (i.e., the resistive layer 64) at the locations where the seventh surface modification structure 97 is provided, compared to the portions of the surface of the resistive layer 64 without the seventh surface modification structure 97 (and also the portions without the sixth surface modification structure 96). For the liquid itself, this results in a relatively large contact angle with the surface of the resistive layer 94 in the regions with the seventh surface modification structure 97, thus the liquid experiences relatively less diffusion on surface 62b. Therefore, the seventh surface modification structure 97 is provided to suppress or reduce the liquid flow characteristics of the surface of the resistive layer 64 in the regions where the seventh surface modification structure 97 is provided.

[0199] The seventh surface modification structure 97 is configured to extend along the center of the resistive layer 64 (parallel to the longitudinal axis L2). The seventh surface modification structure 97 serves to impede the flow of liquid in the direction toward the center of the resistive layer 64. Similar to the third surface modification structure 93, the seventh surface modification structure 97 can be considered to act as a barrier to limit the flow of liquid along the surface of the resistive layer 64. In this example, the seventh surface modification structure 97 is used to keep the liquid within a region close to the opening of the capillary 66. The seventh surface modification structure 97 reduces the chance of liquid transfer from one capillary 66 to another. This can be used to prevent excess liquid from one capillary 66 from transferring to another and causing overflow or otherwise adversely affecting evaporation performance. In other cases, the seventh surface modification structure 97 allows any condensed liquid formed due to aerosol condensation in the central air channel 73, but unable to pass through the air channel 73 and subsequently condense on the surface of the resistive layer 64, to remain near the corresponding capillary 66 (again, allowing the condensed liquid to pass through the corresponding capillary 66 rather than any other area of ​​the resistive layer 64). Therefore, due to the seventh surface modification structure 97, the movement of liquid on the surface of the resistive layer 64 is constrained or limited, so that the liquid is essentially kept in a suitable area on the surface of the resistive layer 64.

[0200] Therefore, according to Figure 10a and Figure 10b In a third implementation, the surface of the resistive layer 64 of the heater assembly 6 is provided with one or more surface modification structures 96, 97, which are arranged to alter the flow of the liquid aerosol generating material on the surface of the resistive layer 64. In the described example, the sixth surface modification structure 96 is configured to relatively promote the flow of the liquid aerosol generating material on the surface of the resistive layer 64 to facilitate the diffusion of the liquid aerosol generating material, thereby improving the aerosol generation performance of the heater assembly 6, while the seventh surface modification structure 97 is configured to relatively reduce the flow of the liquid aerosol generating material on the surface of the resistive layer 64 to retain liquid in certain portions of the surface of the resistive layer 64 (i.e., to prevent passage between certain capillaries 66, which could lead to liquid overload in certain areas). However, it should be understood that... Figure 10a and Figure 10b The implementation shown is merely an example, and in other implementations, the settings of surface modification structures 96 and 97 may differ from those shown.

[0201] For example, in some implementations, it may be necessary to switch the relative increase and decrease of the surface energy of the surface of the resistive layer 64 provided by the sixth surface modification structure 96 and / or the seventh surface modification structure 97. That is, in some implementations, the sixth surface modification structure 96 may alternatively be configured to relatively reduce the surface energy compared to the portion of the surface of the resistive layer 64 without the surface modification structure, while the seventh surface modification structure 97 may additionally or alternatively be configured to relatively increase the surface energy compared to the portion of the surface of the resistive layer 64 without the surface modification structure. Thus, the sixth surface modification structure 96 can be configured to effectively reduce the diffusion of aerosol-generating material on the surface of the resistive layer 64, thereby reducing the rate of aerosol generation. Similarly, the seventh surface modification structure 97 can be configured to promote the flow of aerosol-generating material toward certain areas (e.g., capillary 66) so that any leaked or condensed liquid is returned to capillary 66.

[0202] Therefore, it should be understood that surface modification structures 96, 97 can be provided on the surface of the resistive layer 64 of the heater assembly 6 to influence the flow or transport of the liquid aerosol generating material across the surface of the resistive layer 64. Depending on the specific characteristics of the heater assembly 6 and its interaction with the liquid aerosol generating material, the surface modification structures 96, 97 can be configured in any desired manner to achieve specific results. Although Figure 10a and Figure 10b The examples demonstrate surface modification structures for increasing surface energy (i.e., the sixth surface modification structure 96) and for decreasing surface energy (i.e., the seventh surface modification structure 97), but it should be understood that some implementations may employ only one type of surface modification structure. Additionally, although Figure 10a and Figure 10b The specific shapes and distributions of surface modification structures 96 and 97 are shown, but it should be understood that this is merely an example, and other implementations may have surface modification structures with different shapes and / or different distributions on the surface of the resistive layer 64. Furthermore, as mentioned above, in some implementations, surface modification structures may be provided on the entire surface of the resistive layer 64.

[0203] The heater assembly 6, as described above, is typically configured as a relatively small component with a relatively small coverage area (compared to more conventional heater assemblies such as wicks and coils). This is partly because the capillary 66 is formed via a manufacturing process within the heater assembly 6 (i.e., by processing the capillary, for example, through a laser drilling process), and can therefore be designed to achieve the desired delivery of liquid aerosol generating material to the resistive layer 64. By providing a smaller component, material waste can be reduced (e.g., when the atomizing cartridge 3 is discarded). Furthermore, by applying one or more surface-modified structures, the performance of the heater assembly 6 can be tailored to achieve specific goals or performance characteristics.

[0204] It should be understood that the configuration providing the atomizing cartridge 3 housing the heater assembly 6 is an exemplary configuration of such atomizing cartridge 3. The principles of this disclosure also apply to other configurations of the atomizing cartridge 3 (e.g., including those with...). Figure 1 and Figure 2 Components that are similar to or different from the components shown, and those that are... Figure 2 (The layout shown may be similar or different). That is, the relative positions of the atomizing cartridge 3 and the heater assembly 6 within the atomizing cartridge 3 are not important to the principles of this disclosure. Broadly speaking, the atomizing cartridge may include a top (with a mouthpiece orifice 41) and a bottom. In the example shown above, the heater assembly 6 is arranged below the reservoir 46, horizontal or substantially horizontal (e.g., within 5°) to the longitudinal axis of the atomizing cartridge 3, and arranged in an airflow path substantially perpendicular to the longitudinal axis of the heater assembly. However, this is not necessarily the case, and in other implementations, the atomizing cartridge 3 may be configured differently depending on the specific design and application. For example, the heater assembly 6 may be arranged such that the airflow is parallel or substantially parallel to the longitudinal axis of the heater assembly (e.g., within 5°), for example, along the exposed surface of the resistive layer 64. For example, the upper clamping unit 5 may not have a central air passage 58, but rather the air passage may be provided on one side of the upper clamping unit 5. Air can enter the atomizing cartridge 3 through a suitable inlet, flow along the longitudinal surface of the heater assembly 6 (and along the resistive layer 64), and then pass vertically or substantially vertically (e.g., within 5° of the vertical direction) through an air passage 58 located at one end of the upper sealing unit 5 (e.g., the end opposite the air inlet). The housing 4 and the mouthpiece orifice 41 can be suitably constructed. In such an example, the entire lower surface of the heater assembly 6 can be exposed to the reservoir 46. In this implementation, the capillary 66 can be arranged throughout the heater assembly 6, not just within the central portion 67 of the heater assembly 6 (assuming the resistive layer 64 can be connected to a power source). Therefore, although already... Figure 1 and Figure 2 The heater assembly 6 is described in the specific text of the exemplary atomizing cartridge 3, but the principles described herein can be applied to different heater assemblies used in different atomizing cartridges 3.

[0205] exist Figure 2 In the example shown, the contact pad 75 directly contacts the resistive layer 64 of the heater assembly 6. However, the atomizing cartridge 3 can be arranged in any suitable manner to facilitate electrical contact between the aerosol supply device 2 and the heater assembly 6. For example, in some implementations, wires or other conductive elements may extend between the resistive layer 64 and the contact pad 75 of the atomizing cartridge 3. This may be especially true when the maximum dimension of the heater assembly 6 (e.g., its length) is less than the minimum distance between the contact pads 75. The distance between the contact pads 75 can be determined by the electrical contacts on the aerosol supply device 2.

[0206] Furthermore, in the described example, the heater assembly 6 is oriented such that the resistive layer 64 faces the bottom of the atomizing cartridge 3. However, the orientation of the heater assembly 6 is not limited to this, and in other implementations, the heater assembly 6 may be oriented in an alternative configuration, for example, where the resistive layer faces away from the bottom of the atomizing cartridge 3.

[0207] It should also be understood that although the atomizing cartridge 3 including the heater assembly 6 has been described above, in some implementations, the heater assembly 6 may be disposed within the aerosol supply device 2 itself. For example, the aerosol supply device 2 may include the heater assembly 6 and a removable cartridge (including a reservoir of liquid aerosol generating material). The heater assembly 6 is configured to contact the liquid fluid in the cartridge (e.g., via a suitable wicking element or via an additional fluid delivery mechanism). Alternatively, in addition to the heater assembly 6, the aerosol supply device 2 may also include an integral liquid storage area that is refillable with liquid. More broadly, an aerosol supply system (which includes a separable aerosol supply device and an atomizing cartridge / cartridge or an integrated aerosol supply device and cartridge) includes a heater assembly.

[0208] Furthermore, the heater assembly 6 has already been described above, wherein a resistive layer 64 is disposed on the surface of the corresponding substrate. Figure 2 In the aerosol supply system 1, power is supplied to the resistive layer 64 via the contact pad 75. Thus, current can flow from one end of the resistive layer 64 to the other to cause heating of the resistive layer 64. However, it should be understood that the power used to cause heating of the resistive layer 64 can be provided by alternative means, and specifically, by induction heating. In this implementation, the aerosol supply system 1 is provided with a coil (called a drive coil) to which alternating current is applied. This subsequently generates an alternating magnetic field. When the resistive layer 64 is exposed to the alternating magnetic field (and it has sufficient strength), the alternating magnetic field induces currents (eddy currents) in the resistive layer 64. Due to the resistance of the resistive layer 64, these currents can cause Joule heating of the resistive layer 64. Depending on the material forming the resistive layer 64, additional heat can be generated by hysteresis if the material is ferromagnetic or ferrimagnetic. More generally, resistive layer 64 is an example of a heater layer of heater assembly 6, which is configured to generate heat when supplied with energy (e.g., electrical energy), which may be provided, for example, by direct contact or via induction. Other ways in which the heater layer generates heat are also considered within the principles of this disclosure.

[0209] Furthermore, it should be understood that in some implementations, one or more additional layers, such as a protective layer, may be disposed on top of the resistive layer 64. In this implementation, the capillary 66 still extends to the opening in the resistive layer 64, but may additionally extend through the additional one or more layers. More broadly, the capillary 66 extends through the heater assembly 6 to an opening on the surface of the heater assembly 6 that includes the resistive layer 64, including openings in the resistive layer 64 itself and openings in any additional layers above the resistive layer 64.

[0210] Figure 11 An exemplary method for manufacturing heater assembly 6 is shown.

[0211] The method begins in step S11, providing a substrate 62. The manner in which the substrate 62 is formed is not important to the principles of this disclosure. For example, the substrate 62 can be cut from a portion of cultured quartz, or formed via a sintering process of sintering quartz powder / fiber.

[0212] The method then proceeds to step S12, whereby a resistive layer 64 is formed on the surface of the substrate 62. The manner in which the resistive layer 64 is formed on the surface of the substrate 62 is not important to the principles of this disclosure. For example, the resistive layer 64 may be a sheet of metal (e.g., titanium) adhered, welded, etc., to the substrate 62. Alternatively, the resistive layer 64 may be formed using the substrate 62 as a base via vapor phase or chemical deposition techniques.

[0213] It should also be understood that step S12 may alternatively occur before step S11. For example, an alternative is to use the resistive layer 64 as a base to grow or culture substrate 62.

[0214] In the described example, after step S12, the method proceeds to step S13. In step S13, one or more capillaries 66 are formed in the substrate 62 / resistive layer 64. As described above, the capillaries 66 extend from the surface of the substrate 62 / heater assembly 6 through the resistive layer 64 disposed on a first surface of the substrate 62. That is, the capillaries 66 extend all the way through the heater assembly 6. The capillaries 66 can be formed by laser drilling as described above or by any other suitable technique.

[0215] It should be understood that step S13 can be performed before step S12 (and similarly, step S13 can be performed after step S11, wherein step S12 is performed before step S11). That is, the capillary 66 can be formed in the substrate 62 before the resistive layer 64 is applied.

[0216] In step S14, one or more surface modification structures are provided to the heater assembly 6. As described above, surface modification structures 92-97, 191 may be provided on at least a portion of one of the surface of the resistive layer 64, the second surface 62b of the substrate 62, and the sidewalls / surfaces of one or more capillaries 66. These surface modification structures are provided to regulate the flow of aerosol-generating material capable of flowing along at least a portion of one of the surface of the resistive layer 64, the second surface 62b of the substrate 62, and the side surfaces of one or more capillaries 66. As described above, the surface modification structures may include surface coatings and / or surface treatments, therefore, in step S14, any suitable technique may be employed to provide the desired surface modification structure, such as CVD or polishing.

[0217] Broadly speaking, it should be understood that Figure 11 The method described herein is merely an exemplary method, and adaptations to the steps of the method or the order of the steps are contemplated within this disclosure, for example, as described above.

[0218] After step S14, heater assembly 6 is formed and can then be assembled to form atomizing cartridge 3 (or more generally, heater assembly 6 may be located in aerosol supply system 1).

[0219] According to the principles of this disclosure, a heater device including a heater assembly 6 is also provided for use in an aerosol supply device including an aerosol supply system 1. The heater device includes: a substrate, which may include a substrate 62; a heater layer device, which may include a resistive layer 64, disposed on at least a first surface of the substrate and configured to generate heat; and a capillary device, which may include a capillary tube 66, extending from a second surface of the substrate and passing through the substrate and the heater layer device, the capillary device being configured to supply aerosol generating material from the second surface of the substrate to the heater layer device. The heater device includes a surface-modified structure device, which may include surface-modified structures 92-97, 191, configured to regulate the flow of aerosol generating material capable of flowing along at least a portion of one or more of the surface of the heater layer device, the second surface of the substrate, and the side surface of the capillary device.

[0220] Therefore, a heater assembly for an aerosol supply system has been described, comprising: a substrate; a heater layer disposed on at least a first surface of the substrate and configured to generate heat; and one or more capillaries extending from a second surface of the substrate and through the substrate and the heater layer, the capillaries being configured to supply aerosol-generating material from the second surface of the substrate to the heater layer. The heater assembly includes a surface-modified structure configured to regulate the flow of aerosol-generating material capable of flowing along at least a portion of one or more of the surface of the heater layer, the second surface of the substrate, and the side surfaces of one or more capillaries. Consumables for use with aerosol supply devices, aerosol supply devices, aerosol supply systems, methods of manufacturing heater assemblies, and heater devices have also been described.

[0221] Alternatively, this disclosure can be summarized as providing a heater assembly for an aerosol supply system, the heater assembly 6 having: a substrate 62; a heater layer 64 disposed on at least a first surface of the substrate 62 and configured to generate heat; and one or more capillaries 66 extending from a second surface 62b of the substrate 62 and through the substrate 62 to the heater layer 64, the one or more capillaries 66 being configured to supply aerosol generating material from the second surface 62b of the substrate to the heater layer 64. The heater assembly 6 also includes surface modification structures 92-97, 191, the surface modification structures being configured to regulate the flow of aerosol generating material capable of flowing along at least a portion of one or more of the surface of the heater layer 64, the second surface 62b of the substrate 62, and the side surfaces of one or more capillaries 66.

[0222] While the above embodiments focus in some aspects on specific exemplary aerosol supply systems, it should be understood that the same principles can be applied to aerosol supply systems using other technologies. That is, the specific manner in which various aspects of the aerosol supply system function are not directly related to the basic principles of the examples described herein.

[0223] To address various problems and improve the prior art, this disclosure illustrates, by way of description, multiple embodiments in which the claimed invention can be implemented. The advantages and features of this disclosure are merely representative examples of embodiments and are not exhaustive and / or exclusive. They are intended only to aid in understanding and teaching the claimed invention. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of this disclosure should not be considered as limitations on this disclosure as defined by the claims or on equivalents of the claims, and other embodiments may be utilized and modifications may be made without departing from the scope of the claims. Various embodiments may suitably include various combinations of, constitute, or substantially constitute various combinations of the disclosed elements, components, features, parts, steps, devices, etc., other than those specifically described herein, and therefore should be recognized that features of dependent claims may be combined with features of independent claims in combinations other than those expressly stated in the claims. This disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. An aerosol supply system, the aerosol supply system comprising: Heater assembly, the heater assembly comprising: Base; A heater layer is disposed on at least a first surface of the substrate and configured to generate heat; A first group of one or more capillaries, extending from a second surface of the substrate through the substrate and the heater layer, and having a first characteristic; and A second group of one or more capillaries extends from the second surface of the substrate through the substrate and the heater layer and has a second characteristic different from the first characteristic; and An aerosol generating material storage area is in fluid communication with the second surface of the substrate, and the aerosol generating material storage area includes a first aerosol generating material and a second aerosol generating material. The second aerosol-generating material has a higher viscosity than the first aerosol-generating material, and In this configuration, one or more capillaries in the first group are configured to impede the flow of the second aerosol-generating material.

2. The aerosol supply system according to claim 1, wherein, The first group of one or more capillaries is configured to impede the flow of the second aerosol generating material along the first group of one or more capillaries.

3. The aerosol supply system according to claim 1 or 2, wherein, The second set of one or more capillaries is configured to allow the first aerosol generating material and the second aerosol generating material to flow along the second set of one or more capillaries.

4. The aerosol supply system according to any one of the preceding claims, wherein, The aerosol generated by the first aerosol generating material when it is aerosolized by the heater layer has different characteristics compared to the aerosol generated by the second aerosol generating material when it is aerosolized by the heater layer.

5. The aerosol supply system according to any one of the preceding claims, wherein, The first set of one or more capillaries is disposed in one or more regions of the heater assembly such that it impedes or prevents the second aerosol generating material from being supplied to the heater layer in the one or more regions of the heater assembly.

6. The aerosol supply system according to claim 5, wherein, The heater layer in one or more regions of the heater assembly is configured such that, in use, the one or more regions have different operating characteristics compared to the rest of the heater layer.

7. The aerosol supply system according to any one of the preceding claims, wherein, The first group of one or more capillaries differs from the second group of one or more capillaries in that at least one of the following is true: the size of the cross-section, the shape of the cross-section, and the nature of the side surfaces of the one or more capillaries.

8. The aerosol supply system according to any one of the preceding claims, wherein, The aerosol generating material storage section includes a first aerosol generating material storage section for storing the first aerosol generating material and a second aerosol generating material storage section for storing the second aerosol generating material, wherein both the first aerosol generating material storage section and the second aerosol generating material storage section are configured to be in fluid communication with the second surface of the substrate of the heater assembly.

9. A consumable for use with an aerosol supply system to generate aerosols, said consumable comprising: Heater assembly, the heater assembly comprising: Base; A heater layer is disposed on at least a first surface of the substrate and configured to generate heat; A first group of one or more capillaries, extending from a second surface of the substrate through the substrate and the heater layer, and having a first characteristic; and A second group of one or more capillaries extends from the second surface of the substrate through the substrate and the heater layer and has a second characteristic different from the first characteristic; and An aerosol generating material storage area is in fluid communication with the second surface of the substrate, and the aerosol generating material storage area includes a first aerosol generating material and a second aerosol generating material. The second aerosol-generating material has a higher viscosity than the first aerosol-generating material, and In this configuration, one or more capillaries in the first group are configured to impede the flow of the second aerosol-generating material.

10. A method of manufacturing an aerosol supply system or a consumable for use with an aerosol supply system, the aerosol supply system or the consumable comprising a heater assembly, the heater assembly including a substrate and a heater layer disposed on at least a first surface of the substrate and configured to generate heat, the aerosol supply system or the consumable further comprising an aerosol generating material storage portion, the aerosol generating material storage portion including a first aerosol generating material and a second aerosol generating material, wherein the second aerosol generating material has a higher viscosity than the first aerosol generating material, wherein the method comprises: A first group of one or more capillaries is provided, the first group of one or more capillaries extending from a second surface of the substrate through the substrate and the heater layer and having a first characteristic; as well as A second group of one or more capillaries is provided, the second group of one or more capillaries extending from the second surface of the substrate through the substrate and the heater layer and having a second characteristic different from the first characteristic. In this configuration, one or more capillaries in the first group are configured to impede the flow of the second aerosol-generating material.

11. An aerosol supply device, the aerosol supply device comprising: Heater device, the heater device comprising: Base; A heater layer device is disposed on at least a first surface of the substrate and configured to generate heat; A first set of capillary devices extends from the second surface of the substrate through the substrate and the heater layer device and has a first characteristic; and A second set of capillary devices extends from the second surface of the substrate through the substrate and the heater layer device and has a second characteristic different from the first characteristic; and An aerosol-generating material storage device is in fluid communication with the second surface of the substrate, and the aerosol-generating material storage device includes a first aerosol-generating material and a second aerosol-generating material. The second aerosol-generating material has a higher viscosity than the first aerosol-generating material, and The first set of capillary devices is configured to impede the flow of the second aerosol-generating material.

12. A heater assembly for an aerosol supply system, the heater assembly comprising: Base; A heater layer is disposed on at least a first surface of the substrate and configured to generate heat; as well as One or more capillaries extend from a second surface of the substrate and through the substrate and the heater layer, the one or more capillaries being configured to supply aerosol-generating material from the second surface of the substrate to the heater layer. The heater assembly includes a surface-modified structure configured to regulate the flow of aerosol-generating material capable of flowing along at least a portion of one or more of the surface of the heater layer, the second surface of the substrate, and the side surfaces of one or more capillaries.

13. The heater assembly of claim 12, wherein, The surface modification structure includes at least one of a surface coating and a surface treatment.

14. The heater assembly according to claim 12 or 13, wherein, The surface-modified structure is configured to facilitate the flow of aerosol-generating material capable of flowing along at least one of the surfaces of the heater layer, the second surface of the substrate, and the side surfaces of the one or more capillaries.

15. The heater assembly according to claim 12 or 13, wherein, The surface-modified structure is configured to impede the flow of aerosol-generating material that can flow along at least one of the surface of the heater layer, the second surface of the substrate, and the side surfaces of the one or more capillaries.

16. The heater assembly according to any one of claims 12 to 15, wherein, The surface modification structure is disposed on at least a portion of the second surface of the substrate and configured to adjust the properties of at least a portion of the second surface of the substrate relative to the flow of aerosol generating material capable of flowing along the second surface of the substrate.

17. The heater assembly of claim 16, wherein, The surface-modified structure is configured to facilitate the flow of aerosol-generating material that can flow along the second surface of the substrate, such that the aerosol-generating material can flow toward the openings of the one or more capillaries.

18. The heater assembly of claim 16, wherein, The surface-modified structure is configured to impede the flow of aerosol-generating material that can flow along the second surface of the substrate, thereby reducing the flow of aerosol-generating material toward the openings of the one or more capillaries.

19. The heater assembly according to claim 17 or 18, wherein, The surface modification structure is disposed on at least a portion of the second surface of the substrate surrounding the opening of at least one of the one or more capillaries.

20. The heater assembly according to any one of claims 12 to 19, wherein, The surface modification structure is disposed on at least a portion of the side surface of the one or more capillaries and configured to modulate the characteristics of at least a portion of the side surface of the one or more capillaries relative to the flow of aerosol generating material capable of flowing along the side surface of the one or more capillaries.

21. The heater assembly of claim 20, wherein, The surface-modified structure is configured to facilitate the flow of aerosol-generating material that can flow along the side surface of the one or more capillaries, allowing the aerosol-generating material to flow through the one or more capillaries at a greater rate.

22. The heater assembly of claim 20, wherein, The surface-modified structure is configured to impede the flow of aerosol-generating material that can flow along the side surface of the one or more capillaries, so that the aerosol-generating material can flow through the one or more capillaries at a lower rate.

23. The heater assembly according to any one of claims 12 to 22, wherein, The surface modification structure is disposed on at least a portion of the surface of the heater layer and configured to modulate the characteristics of at least a portion of the surface of the heater layer relative to the flow of aerosol generating material capable of flowing along the surface of the heater layer.

24. The heater assembly of claim 23, wherein, The surface-modified structure is configured to facilitate the flow of aerosol-generating material that can flow along the surface of the heater layer, such that the aerosol-generating material can flow out from openings in the heater layer of the one or more capillaries.

25. A consumable for use with an aerosol supply device, the consumable comprising an aerosol generating material storage portion, an airflow path, and a heater assembly according to any one of claims 12 to 24, wherein the heater assembly is configured such that a second surface of the substrate is in fluid communication with the aerosol generating material storage portion, and the heater layer is in fluid communication with the airflow path.

26. An aerosol supply device for use with consumables, the device comprising an airflow path and a heater assembly according to any one of claims 12 to 24, wherein the heater assembly is configured such that the heater layer is provided in fluid communication with the airflow path.

27. An aerosol supply system comprising an aerosol generating material storage portion, an airflow path, and a heater assembly according to any one of claims 12 to 24, wherein the heater assembly is configured such that a second surface of the substrate is in fluid communication with the aerosol generating material storage portion, and the heater layer is in fluid communication with the airflow path.

28. A method of manufacturing a heater assembly for an aerosol supply system, the heater assembly comprising: Base; A heater layer is disposed on at least a first surface of the substrate and configured to generate heat; and one or more capillaries extending from a second surface of the substrate and through the substrate and the heater layer, the one or more capillaries being configured to supply aerosol-generating material from the second surface of the substrate to the heater layer, wherein the method includes: A surface modification structure is provided, the surface modification structure being configured to regulate the flow of aerosol generating material capable of flowing along at least a portion of one of the surface of the heater layer, the second surface of the substrate, and the side surfaces of the one or more capillaries.

29. A heater device for an aerosol supply device, the heater device comprising: Base; A heater layer device is disposed on at least a first surface of the substrate and configured to generate heat; as well as A capillary device extends from a second surface of the substrate and through the substrate and the heater layer device, the capillary device being configured to supply aerosol-generating material from the second surface of the substrate to the heater layer device. The heater device includes a surface-modified structure device configured to regulate the flow of aerosol-generating material capable of flowing along at least a portion of one or more of the surface of the heater layer device, the second surface of the substrate, and the side surface of the capillary device.

Images