Cartridge for use in an aerosol generating system and an aerosol generating system including said cartridge

Abstract

A cartridge for use in an aerosol generation system is provided. The cartridge includes a porous ceramic body (302) having a porosity of 30% to 65%. The cartridge also includes a mesh heater (304) engaged with the porous ceramic body, the mesh heater including a plurality of openings, each opening having a dimension of 50 microns to 200 microns. The mesh heater is a hybrid mesh heater including a network of wires and fibers, the fibers having a different material composition than the wires. An aerosol generation system including the cartridge is also provided.

Description

Technical Field

[0001] The present invention relates to a cartridge for use in an aerosol generating system. The present invention also relates to an aerosol generating system comprising such a cartridge.

Background Art

[0002] One type of aerosol generating system is an electrically operated smoking system. A handheld electrically operated smoking system is known, which consists of an aerosol generating device comprising a battery and control electronics, and a cartridge comprising a supply of an aerosol-forming substrate and an electrically operated vaporizer. A cartridge comprising both a supply of an aerosol-forming substrate and a vaporizer is sometimes referred to as an “atomizer”. The vaporizer typically comprises a coil of heater wire wound around an elongate wick immersed in a liquid aerosol-forming substrate. The cartridge portion generally includes not only a supply of an aerosol-forming substrate and an electrically operated vaporizer, but also a mouthpiece through which the user draws the aerosol into their mouth during use.

[0003] However, these cartridges can be relatively expensive to manufacture. This is because the manufacture of the wick and coil assembly can be difficult. Also, the electrical contacts between the coil of heater wire and the electrical contacts through which current is supplied from the device portion must be handled delicately during manufacture. Further, these cartridges include a mouthpiece portion for protecting the delicate wick and coil assembly during transport. Including a complete and robust mouthpiece in each cartridge means that the material cost of each cartridge is high.

[0004] It is desirable to provide a cartridge for use in an aerosol generating system that is simple and inexpensive to manufacture, robust, and that can provide more efficient aerosol generation than known cartridges. It is also desirable to provide an aerosol generating system incorporating such a cartridge. [Overview of the project]

[0005] According to this disclosure, a cartridge is provided. The cartridge may be suitable for use in an aerosol generating system. The cartridge may comprise a porous ceramic body. The porous ceramic body may have a porosity of 30% to 65%. The cartridge may comprise a mesh heater. The mesh heater may engage with the porous ceramic body. The mesh heater may include a plurality of openings. Each opening may have dimensions of 50 to 200 microns.

[0006] According to a first embodiment of the present disclosure, a cartridge for use in an aerosol generating system is provided. The cartridge comprises a porous ceramic body having a porosity of 30% to 65%. The cartridge comprises a mesh heater that engages with the porous ceramic body. The mesh heater includes a plurality of openings, each opening having dimensions of 50 to 200 microns.

[0007] According to a second embodiment of the present disclosure, a cartridge for use in an aerosol generating system is provided. The cartridge comprises a porous ceramic body and a mesh heater that engages with the porous ceramic body. The mesh heater is a hybrid mesh heater comprising a network of wires and fibers, wherein the fibers have a different material composition from the wires.

[0008] In the cartridge of the second embodiment, the porous ceramic body may have a porosity of 30% to 65%. The mesh heater may include a plurality of openings, each of which may have dimensions of 50 to 200 microns.

[0009] The following features relating to the cartridge are applicable to the cartridge of the first embodiment and the cartridge of the second embodiment.

[0010] During use, the mesh heater can heat the liquid aerosol-forming substrate. The mesh heater can heat the liquid aerosol-forming substrate to form an aerosol, or a vapor that subsequently forms an aerosol. Advantageously, the mesh heater can provide efficient aerosol generation.

[0011] The porosity of the porous ceramic body may allow it to hold a liquid aerosol-forming substrate. The porous ceramic body may hold, or be configured to hold, at least 0.05, 0.1, 0.2, 0.5, or 1 ml of liquid aerosol-forming substrate.

[0012] Each opening has dimensions of 50 to 200 microns. The liquid aerosol-forming substrate may be drawn into the openings of the mesh heater. The liquid aerosol-forming substrate may be drawn from the porous ceramic body into the openings of the mesh heater. The liquid aerosol-forming substrate may be drawn into the openings of the mesh heater by capillary action or wicking. Advantageously, this can improve, for example, the transport of the liquid aerosol-forming substrate from the porous ceramic body into the openings of the mesh heater.

[0013] A mesh heater may include the arrangement of openings surrounded by a solid material, such as wire. Each opening of the mesh heater acts as a capillary channel and therefore can draw liquid aerosol-forming substrate into the opening. The liquid aerosol-forming substrate may be drawn into the opening by capillary action or wicking. Thus, each opening of the mesh heater can be substantially completely occupied by the liquid aerosol-forming substrate. This may not be the case, for example, if a large opening is present. In the case of a large opening, the liquid aerosol-forming substrate may only form a thin layer on the solid material surrounding each opening. Substantially complete occupancy of the openings by the liquid aerosol-forming substrate contributes to improving the efficiency of aerosol generation in the present invention.

[0014] Advantageously, the inventors have found that the porous ceramic body having a porosity of 30% to 65% and the openings of the mesh heater, each having dimensions of 50 to 200 microns, enable efficient transport of the liquid aerosol-forming substrate through the porous ceramic body to the openings of the mesh heater, and, more importantly, enable efficient aerosol generation associated with heating by the mesh heater. While we do not wish to be bound by theory, it is believed that there is a certain degree of synergistic effect between the porous ceramic body having a porosity of 30% to 65% and the openings of the mesh heater having dimensions of 50 to 200 microns, thereby providing this efficient transport of the liquid aerosol-forming substrate.

[0015] As used herein, the term “aerosol” refers to the dispersion of solid particles or droplets, or a combination of solid particles and droplets, in a gas. Aerosols may be visible or invisible. Aerosols may include not only vapors of substances that are normally liquid or solid at room temperature, but also solid particles or liquid droplets, or a combination of solid particles and liquid droplets.

[0016] As used herein, the term “aerosol-forming substrate” refers to a substrate having the ability to release volatile compounds that can form aerosols. The volatile compounds may be released by heating or burning the aerosol-forming substrate.

[0017] The aerosol-forming substrate may contain nicotine. The aerosol-forming substrate may contain plant-derived materials. The aerosol-forming substrate may contain homogenized plant-derived materials. The aerosol-forming substrate may contain tobacco. The aerosol-forming substrate may contain tobacco-containing materials. The tobacco-containing materials may contain volatile tobacco-flavoring compounds. These compounds may be released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may contain homogenized tobacco materials. The aerosol-forming substrate may contain other additives and components such as flavoring agents.

[0018] As used herein, the term “dimensions of an opening” refers to the dimension measured between two opposing surfaces of an opening. Therefore, for example, if an opening is enclosed by a wire, the dimension of the opening does not include the thickness of the wire. The dimension may pass through the centroid of the cross-section of the opening. For example, if the opening has a substantially square cross-section, the dimension of the opening may be the side length of the square. If the opening has a substantially circular cross-section, the dimension of the opening may be the diameter of the circle. If the opening has a substantially rectangular cross-section, the dimension of the opening may be the length of the long side or short side of the rectangle. If the opening has an irregular cross-section, the dimension of the opening may be the average opening dimension. The dimensions of openings referred to herein were measured using a microscope, but any suitable method may be used.

[0019] As used herein, the term "porosity" refers to a measure expressed as a percentage, obtained by dividing the volume of accessible pores, or empty spaces, by the total volume of the body. The porosity referred to herein was measured by mercury porosimetry.

[0020] Pores of different shapes and sizes may be present within the porous ceramic body. The pore size distribution is defined as the statistical distribution of the diameters of the largest spheres that can fit inside the pores at a given point. As used herein, the term “average pore size” refers to the average of this pore size distribution. The pore sizes referred to herein were obtained using mercury porosimetry.

[0021] As used herein, the term “mesh heater” refers to a heater comprising an arrangement of a solid material that can be heated. The solid material is arranged to have a plurality of openings extending through it. A mesh heater may include, for example, a network of wires or a perforated sheet. A mesh heater may be heated by any suitable method. For example, a mesh heater, or a part thereof, may be heated by resistance heating or induction heating.

[0022] As used herein, the term “capillary action” refers to the ability of a liquid to flow in a narrow space without the help of external forces such as gravity, or even against external forces. The effect of capillary action, or wicking, can be seen in the suction of liquid into thin tubes and porous materials.

[0023] As used herein, the term “bulk liquid aerosol-forming substrate movement direction” refers to the net movement direction of the liquid aerosol-forming substrate.

[0024] As used herein, the term “planar” is used to mean substantially two-dimensional. Planar components may extend at least twice, five times, or ten times further in the first direction and the second direction perpendicular to the first direction than in the third direction perpendicular to the first and second directions.

[0025] As used herein, the term “flat” refers to a substantially two-dimensional topological manifold. Thus, a flat mesh heater extends substantially more along the surface in two dimensions than in three dimensions. The dimensions of a flat mesh heater in two dimensions within a surface may be at least 2, 5, or 10 times larger than those in three dimensions perpendicular to the surface. An example of a substantially flat mesh heater is a structure between two substantially parallel surfaces, where the distance between these two virtual surfaces is substantially smaller than the extension within those surfaces. In some embodiments, a substantially flat mesh heater is planar. In other embodiments, a substantially flat mesh heater is curved along one or more dimensions, forming, for example, a dome or bridge shape. In embodiments, a substantially flat mesh heater may engage with the surface of a porous ceramic body.

[0026] As used herein, the term “heater assembly” refers to the mesh heater and porous ceramic body of the cartridge.

[0027] As used herein, the term "average" refers to the unweighted average value, unless otherwise specified. Thus, the "average" diameter of five wires is equal to one fifth of the sum of the diameters of the five wires.

[0028] The porous ceramic body has a porosity of 30% to 65%. The porous ceramic body may have a porosity of less than 60%, 55%, 50%, or 45%. Alternatively or additionally, the porous ceramic body may have a porosity greater than 35%, 40%, or 45%. For example, the porous ceramic body may have a porosity of 30% to 60%, or 30% to 55%, or 30% to 50%, or 35% to 65%, or 35% to 60%, or 35% to 55%, or 35% to 50%, or 40% to 65%, or 40% to 60%, or 40% to 55%.

[0029] The porous ceramic body can be configured to supply a given flow rate of the liquid aerosol-forming substrate to the mesh heater during use. For example, the porous ceramic body can be configured to supply at least 0.2, 0.5, or 1 microliter / second of the liquid aerosol-forming substrate to the mesh heater during use. The porous ceramic body can be configured to supply less than 3, 5, or 10 microliters / second of the liquid aerosol-forming substrate to the mesh heater during use. The porous ceramic body can be configured to supply 1 to 3 microliters / second of the liquid aerosol-forming substrate to the mesh heater during use.

[0030] The term "porous ceramic body" can refer to a part or the whole of the ceramic component. For example, the term "porous ceramic body" can refer only to a part of the ceramic component in which the liquid aerosol-forming substrate is held or conveyed to the mesh heater.

[0031] The openings of the mesh heater may each have dimensions of 50 to 150 microns, or 50 to 100 microns, or 60 to 80 microns, or about 70 microns.

[0032] During use, the liquid aerosol-forming substrate can be drawn out from the porous ceramic body into the opening of the mesh heater. The liquid aerosol-forming substrate can be drawn out into the opening of the mesh heater by capillary action.

[0033] The mesh heater may be substantially flat. The mesh heater may be substantially planar. Advantageously, flat or planar mesh heaters are easier to handle during manufacturing and can provide a robust heater assembly structure.

[0034] During use, the direction of movement of the bulk liquid aerosol-forming substrate may be substantially perpendicular to the plane of the mesh heater. This can advantageously improve the transport of the liquid aerosol-forming substrate into the opening of the mesh heater.

[0035] Part or all of the mesh heater may be substantially parallel to the first surface of the porous ceramic body. Advantageously, this can improve the transport of the liquid aerosol-forming substrate from the pores of the porous ceramic body, for example, from the pore openings on the first surface of the porous ceramic body, into the openings of the mesh heater.

[0036] The mesh heater, or a portion thereof, may be adjacent to, fixed to, engaged with, and attached to a porous ceramic body or a first surface of a porous ceramic body. For example, the mesh heater, or a portion thereof, may be embedded in a porous ceramic body. If the mesh heater, or a portion thereof, is embedded in a porous ceramic body, the first surface may not be the outer surface of the porous ceramic body. As used herein, the term “engaged with” may be used to mean fixed, secured, attached, or bonded.

[0037] The mesh heater can be reversibly engaged with the porous ceramic body. It may be possible to engage the mesh heater with the porous ceramic body and to disengage the mesh heater from the porous ceramic body. Alternatively, the mesh heater may be irreversibly engaged with the porous ceramic body.

[0038] When engaging with the porous ceramic body, the position of the mesh heater may be fixed. When engaging with the porous ceramic body, the mesh heater may be adjacent to or in contact with the porous ceramic body.

[0039] The mesh heater may be attached to a porous ceramic body. The mesh heater may be attached to the porous ceramic body by any suitable means. The mesh heater can be attached to the porous ceramic body by one or more soldering points, one or more mechanical fasteners such as clips or bolts, and one or more ceramic coating layers. The mesh heater may be embedded in the porous ceramic body.

[0040] The porous ceramic body may include a second surface substantially opposite to the first surface. During use, the liquid aerosol-forming substrate may move through the porous ceramic body from the second surface to the first surface. The liquid aerosol-forming substrate may move through the porous ceramic body by capillary action. Alternatively, or additionally, an airflow passing through, across, or around the porous ceramic body or mesh heater may create a local pressure gradient in the porous ceramic body, thereby assisting the movement of the liquid aerosol-forming substrate through the porous ceramic body.

[0041] The porous ceramic body may absorb or be configured to absorb a liquid aerosol-forming substrate. For example, the porous ceramic body may absorb or be configured to absorb at least 0.01, 0.02, 0.05, 0.1, or 0.5 ml of liquid aerosol-forming substrate.

[0042] The cartridge may include a liquid aerosol-forming substrate storage component for storing a liquid aerosol-forming substrate. The liquid aerosol-forming substrate storage component may store the liquid aerosol-forming substrate. The liquid aerosol-forming substrate storage component may be in fluid communication with a porous ceramic body, for example, a second surface of a porous ceramic body.

[0043] The liquid aerosol-forming substrate storage component may include a storage section or tank for the liquid aerosol-forming substrate. The porous ceramic body may be in fluid communication with or in contact with the storage section for the liquid aerosol-forming substrate.

[0044] The liquid aerosol-forming substrate storage component may include a material immersed in a liquid aerosol-forming substrate. The liquid aerosol-forming substrate storage component may be positioned to transport the liquid into a porous ceramic body.

[0045] The liquid aerosol-forming substrate storage component may have a fibrous or spongy structure. The liquid aerosol-forming substrate storage component may include capillary material. The liquid aerosol-forming substrate storage component may include bundles of capillaries. For example, the liquid aerosol-forming substrate storage component may include one or more of several fibers or threads, or microtubules. The fibers, threads, or tubes may generally be aligned to transport the liquid into a porous ceramic body.

[0046] The liquid aerosol-forming substrate storage component may contain a sponge-like material or a foam-like material. The structure of the liquid aerosol-forming substrate storage component may form a plurality of small holes or tubes through which the liquid can be transported by capillary action.

[0047] Liquid aerosol-forming substrate storage components may include any suitable material or combination of materials. Examples of suitable materials include sponge or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, foamable metal or plastic materials, fibrous materials such as spun or extruded fibers (cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics, etc.). Liquid aerosol-forming substrate storage components may have any suitable capillary action and porosity for use with different liquid physical properties.

[0048] The cartridge may comprise a liquid aerosol-forming substrate storage component immersed in a liquid aerosol-forming substrate. The liquid aerosol-forming substrate storage component may be in contact with a porous ceramic body. The porous ceramic body may include a first portion. The first portion of the porous ceramic body may be located between the liquid aerosol-forming substrate storage component and the mesh heater. The first portion of the porous ceramic body may include a first surface and a second surface. The second surface may face the first surface. The mesh heater may engage with the first surface. The liquid aerosol-forming substrate storage component may be in contact with the second surface. The mesh heater may include a metal, such as steel, including stainless steel.

[0049] The mesh heater area is 50, 40, or 30 mm². 2 It may be less than this. This could make it possible to incorporate the mesh heater into a handheld system.

[0050] A mesh heater may include a network of wires. The wires may be woven together. A mesh heater may include a woven or unwoven wire mesh. The wires may be conductive.

[0051] The wires may be placed on a single plane. The mesh heater may also be planar. Planar mesh heaters are easy to handle during manufacturing and can provide a robust structure.

[0052] The opening may be defined by being enclosed by a wire. The wire may have a substantially circular, square, rectangular, hexagonal, or irregular cross-section.

[0053] The wires may be formed individually and then braided together. The wires may also be formed by etching a sheet material such as foil. This can be particularly advantageous when the mesh heater includes an array of parallel wires. Alternatively, the wires may be stamped from a conductive foil, such as stainless steel.

[0054] The mesh heater, or wire, may contain or be formed from any material having suitable electrical and mechanical properties. Suitable materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilide), carbon, graphite, metals, alloys, and composite materials made of ceramic and metallic materials. Such composite materials may contain doped or undoped ceramics. An example of a suitable doped ceramic is doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable alloys include stainless steel, constantan, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel, iron, cobalt, stainless steel-based superalloys, Timetal®, iron-aluminum alloys, and iron-manganese-aluminum alloys. Timetal® is a registered trademark of Titanium Metals Corporation. The wire may be coated with one or more electrical insulators. Preferred materials for the mesh heater or wire may be 304, 316, 304L, 316L stainless steel, and graphite. Additionally, the mesh heater or wire may include combinations of the above materials. Combinations of materials may be used to improve the control of the resistance of the mesh heater. For example, a material with high resistivity may be combined with a material with low resistivity. This can be advantageous if one of the materials is more beneficial from another perspective, such as price, machinability, or other physical and chemical parameters.

[0055] The mesh heater may include at least one wire made from a first material and at least one wire made from a second material different from the first material. This may be beneficial for electrical or mechanical reasons. For example, one or more wires may be made from materials that have significantly different resistances at different temperatures, such as an iron-aluminum alloy. This allows for the measurement of the resistance of the wire used to determine the temperature or temperature change. This can be used in a fume extraction detection system and to control the heater temperature to keep it within a desired temperature range. Rapid temperature changes may also be used as a means for the user to detect changes in the airflow passing through the mesh heater resulting from fume extraction of the system.

[0056] A mesh heater may include two or more types of wires formed within a wire mesh. The two types of wires may have different resistivity. Wires with high resistivity are preferably oriented in the direction of current flow and are, for example, nickel-chromium alloy wires. Wires with low resistivity may be arranged substantially perpendicular to the wires with high resistivity. For example, the low-resistivity wires may be stainless steel wires. Advantageously, the relatively inexpensive low-resistivity wires form support for the wires with high electrical resistance. Furthermore, wires with high electrical resistance are generally less malleable than stainless steel wires and are therefore more difficult to manufacture into thin wires.

[0057] Alternatively, the mesh heater may include a carbon fiber fabric. Advantageously, carbon fiber fabrics are generally more flexible than metal meshes.

[0058] The wire may have an average diameter of at least 10, 16, 17, or 30 microns. The wire may have an average diameter of less than 100, 90, 80, 70, 60, 50, 40, or 30 microns. Preferably, the wire may have an average diameter of 15 to 30 microns, or 15 to 20 microns, for example, about 16 or 17 microns.

[0059] Each wire may have a minimum thickness of at least 10, 16, 17, or 30 microns. Each wire may have a minimum thickness of less than 100, 90, 80, 70, 60, 50, 40, or 30 microns.

[0060] The mesh heater may be a hybrid mesh heater. As used herein, the term “hybrid mesh heater” is used to refer to a mesh heater comprising at least one wire and at least one fiber. The mesh heater may include a network of wires and fibers. The wire characteristics and properties described above are equally applicable to the wires of a hybrid mesh heater.

[0061] The fibers may have a different material composition than the wire. The wire and fibers may be woven together. Therefore, a mesh heater may include a woven wire and fiber mesh. The fibers may have an average diameter of 80% to 120% of the average diameter of the wire. The wire and fibers may have substantially the same average diameter.

[0062] The wire may be substantially perpendicular to the fiber.

[0063] The fibers may have an average diameter of at least 10, 16, 17, or 30 microns. The fibers may have an average diameter of less than 100, 90, 80, 70, 60, 50, 40, or 30 microns. Preferably, the fibers may have an average diameter of 15 to 30 microns, or 15 to 20 microns, for example, about 16 or 17 microns. The fibers may include glass fibers. The fibers may include rayon fibers.

[0064] Each fiber may have a minimum thickness of at least 10, 16, 17, or 30 microns. Each fiber may have a minimum thickness of less than 100, 90, 80, 70, 60, 50, 40, or 30 microns.

[0065] The thickness of the mesh heater may be at least 30, 40, or 48 microns. If the mesh heater includes wire, or wire and fiber, the thickness of the mesh heater may be approximately three times the average diameter of the wire or fiber. For example, the thickness of the mesh heater may be 2.5 to 3.5 times the average diameter of the wire or fiber. The thickness of the mesh heater may be less than 300, 250, 200, 150, or 100 microns. The thickness of the mesh heater may be 45 to 100, or 45 to 80, or 45 to 60 microns.

[0066] A mesh heater may include a sheet. The sheet may be made of metal. The sheet may contain a metal such as stainless steel. The sheet may include multiple openings. The sheet may be perforated. Multiple openings may include perforations in the sheet. The sheet may include a heating track, or the heating track may be placed on the sheet. As used herein, the term “heating track” is used to refer to a track, path, or section of material configured to be heated when in use. For example, an electric current may pass through the heating track to resistively heat it when in use. In this case, the heating track may contain a conductive material. Alternatively, the heating track may contain a susceptor material, and the heating track may be inductively heated when in use.

[0067] The mesh heater may engage with the porous ceramic body or the first surface of the porous ceramic body over substantially the entire surface of the mesh heater. The mesh heater may be in contact with the porous ceramic body or the first surface of the porous ceramic body. The mesh heater may be in contact with the porous ceramic body or the first surface of the porous ceramic body over substantially the entire surface of the mesh heater. The mesh heater may engage with the porous ceramic body or the first surface of the porous ceramic body such that there are no points where the gap between the porous ceramic body and the mesh heater exceeds 500, 300, 100, 75, 50, or 25 microns. All points of the mesh heater may be within 500, 300, 100, 75, 50, or 25 microns of at least one point on the porous ceramic body or the first surface of the porous ceramic body. Advantageously, by minimizing any gap between the mesh heater and the porous ceramic body, the transport of the liquid aerosol-forming substrate from the porous ceramic body into the openings of the mesh heater can be improved.

[0068] The porous ceramic body has a relatively low linear coefficient of thermal expansion, for example, 30, 20, or 10x10 at 25 degrees Celsius. -6 This may include materials having a linear coefficient of thermal expansion less than m / (mK). Advantageously, a low coefficient of thermal expansion can reduce the risk of particles detaching from the porous ceramic body when the porous ceramic body is heated by a mesh heater. This risk can be particularly high at the contact point between the mesh heater and the porous ceramic body if the mesh heater is in contact with the porous ceramic body.

[0069] The porous ceramic body may include a material having a linear coefficient of thermal expansion at 25 degrees Celsius, which is 30% to 300% of the linear coefficient of thermal expansion of the mesh heater at 25 degrees Celsius. Advantageously, this can reduce the risk of particles detaching from the porous ceramic body when the porous ceramic body is heated by the mesh heater.

[0070] The porous ceramic body may contain one or more of steatite, alumina, and zirconia. Advantageously, these materials are chemically stable and have relatively low coefficients of thermal expansion.

[0071] The porous ceramic body may contain pores having an average pore size of less than 40, 30, 20, 10, or 8 microns. The porous ceramic body may contain pores having an average pore size of greater than 2.5, 5, 10, or 20 microns. The porous ceramic body may contain pores having an average pore size of 2.5 to 40 microns, or 2.5 to 30 microns, or 2.5 to 20 microns, or 2.5 to 10 microns, or 2.5 to 8 microns, or 5 to 40 microns, or 5 to 30 microns, or 5 to 20 microns, or 5 to 10 microns, or 10 to 40 microns, or 10 to 30 microns, or 10 to 20 microns, or 20 to 40 microns, or 20 to 30 microns, or 30 to 40 microns.

[0072] A preferred porous ceramic body may have a porosity of 30% to 60% and pores having an average pore size of 5 to 30 microns. A particularly preferred porous ceramic body may have a porosity of 40% to 60% and pores having an average pore size of 5 to 10 microns. Another particularly preferred porous ceramic body may have a porosity of 30% to 40% and pores having an average pore size of 20 to 30 microns.

[0073] The porous ceramic body may include a first portion and projections. The projections may be located around the first portion. The projections may extend substantially around the entire periphery of the first portion. The projections may extend substantially perpendicular to the surface of the first portion. Advantageously, the projections may allow the porous ceramic body to withstand large forces during manufacturing and assembly without breakage.

[0074] The first part may include a length, a width perpendicular to the length, and a thickness perpendicular to the length and width. The length and width may be at least twice, three times, or five times the thickness.

[0075] The first part may have a substantially circular cross-section. The first part may have a diameter and a thickness. The diameter may be at least twice, three times, or five times the thickness.

[0076] The first portion may have a thickness of at least 1, 1.5, 2, or 2.5 mm. Advantageously, a greater thickness can improve the strength of the first portion of the porous ceramic body. The first portion may have a thickness of less than 6, 5, or 4 mm. Advantageously, a smaller thickness can improve the wicking ability of the first portion and therefore improve the transport of the liquid aerosol-forming substrate through the first portion. Thus, the first portion may have a thickness of 1–6 mm, or 1–5 mm, or 1.5–5 mm, or 1.5–4 mm.

[0077] The projection may have a width of at least 1, 1.5, 2, or 2.5 mm. The projection may have a width of less than 6, 5, or 4 mm. Therefore, the projection may have a width of 1 to 6 mm, or 1 to 5 mm, or 1.5 to 5 mm, or 1.5 to 4 mm. The width of the projection may be 50% to 150% of the thickness of the first part.

[0078] The first portion of the porous ceramic body may be located between the liquid aerosol-forming substrate storage component and the mesh heater. The first portion of the porous ceramic body may include a first surface and a second surface. The second surface may face the first surface. The mesh heater may engage with the first surface. The liquid aerosol-forming substrate storage component may be in contact with the second surface. Protrusions may extend from the second surface. Protrusions may surround the liquid aerosol-forming substrate storage component.

[0079] The porous ceramic body may include channels extending through it. A first portion of the porous ceramic body may include channels. The channels may extend through the first portion. The channels may extend substantially in the thickness direction of the first portion. The mesh heater may be substantially flat or planar, and the channels may extend substantially perpendicular to the plane of the mesh heater. The channels may have a diameter of at least 300, 400, or 500 microns. The channels may have a diameter of less than 800, 700, or 600 microns. Advantageously, the channels may increase the porosity of the porous ceramic body. This may allow the porous ceramic body to hold more liquid aerosol-forming substrate. Furthermore, the channels may improve the wicking ability of the porous ceramic body. Thus, the channels may improve the transport of liquid aerosol-forming substrate through the porous ceramic body.

[0080] The mesh heater can be attached to a porous ceramic body by one or more solder points. The solder points may contain silver or tin.

[0081] The mesh heater can be attached to the porous ceramic body by providing a metal segment or multiple segments between the porous ceramic body and the mesh heater (for example, by applying the metal segment to the porous ceramic body or by covering the mesh heater with metal), engaging and positioning the mesh heater with the porous ceramic body, and optionally, by melting and solidifying the metal segment while forcing the mesh heater and the porous ceramic body toward each other. As the metal segment solidifies, the metal segment adheres the porous ceramic body to the mesh heater.

[0082] The mesh heater can be attached to the porous ceramic body by providing a metal segment or multiple segments between the mesh heater and the porous ceramic body (for example, by applying the metal segment to the porous ceramic body or by covering the mesh heater with metal), and optionally by forcing the mesh heater and the porous ceramic body toward each other while heating the metal segment. The metal segment can bond the porous ceramic body to the mesh heater.

[0083] When multiple metal segments are used, these segments may be separated by gaps, for example, within the plane of the mesh heater. One or more segments may be blobs or metal parts on the porous ceramic body or the mesh heater, or may include such parts. Thus, multiple separated blobs or metal parts may be present on the porous ceramic body, on the mesh heater, or both.

[0084] Therefore, by attaching the mesh heater to the porous ceramic body as described above, the cartridge may include a metal segment between the porous ceramic body and the mesh heater. The metal segment may contain silver or tin. However, it should be noted that the cartridge may also have a metal segment between the porous ceramic body and the mesh heater for other reasons.

[0085] Metal segments can be used to bond the porous ceramic body to the mesh heater. The metal segments may contain silver or tin.

[0086] A mesh heater, or a portion thereof, may include a metal coating, either entirely or partially. The metal coating may include tin or silver. This may be applied by coating the mesh heater with metal segments.

[0087] The mesh heater may be attached to the porous ceramic body by engaging and positioning the mesh heater with the porous ceramic body, and by arranging the second ceramic coating layer on the mesh heater such that at least a portion of the mesh heater is between the porous ceramic body and the second ceramic coating layer. The porous ceramic body, or the second ceramic coating layer, or both the porous ceramic body and the second ceramic coating layer may then be sintered. Alternatively, or additionally, the porous ceramic body, or the second ceramic coating layer, or both the porous ceramic body and the second ceramic coating layer may be sintered before the second ceramic coating layer is placed on the mesh heater.

[0088] The characteristics and properties of the porous ceramic body can also be applied to the second ceramic coating layer. For example, the characteristics and properties of the material, material properties, pore size, and porosity can all be applied to the second ceramic coating layer.

[0089] Therefore, by attaching the mesh heater to the porous ceramic body as described above, the mesh heater can be positioned between the porous ceramic body and the second ceramic coating layer. However, it should be noted that the cartridge may include the second ceramic coating layer for other reasons.

[0090] The second ceramic coating layer may contain ceramic material. The porous ceramic body may also contain ceramic material. Therefore, both the porous ceramic body and the second ceramic coating layer may contain one or more of alumina, steatite, and zirconia.

[0091] The second ceramic coating layer may have a thickness of less than 5000, 1000, 500, or 200 microns. The second ceramic coating layer may have a thickness of at least 10, 100, 500, or 1000 microns. Therefore, the second ceramic coating layer may have a thickness of 500 to 5000 microns, for example, 1000 to 2000 microns.

[0092] The second ceramic coating layer may be in contact with the mesh heater. The second ceramic coating layer may be in contact with the porous ceramic body. The mesh heater may be attached to the porous ceramic body by the second ceramic coating layer.

[0093] The second ceramic coating layer may cover 80%, 65%, or less than 50% of the mesh heater surface. This may improve aerosol generation compared to a second ceramic coating layer that covers a larger proportion of the mesh heater surface.

[0094] The cartridge may have an air intake. The cartridge may have an air outlet. The air intake may be in fluid communication with the air outlet. The mesh heater may be located downstream of the air intake. The mesh heater may be located upstream of the air outlet.

[0095] The cartridge may be equipped with a mouthpiece. The mouthpiece may be an air outlet or may include an air outlet. When the cartridge is connected to the aerosol generator during use, the user can inhale the mouthpiece of the cartridge. This allows air to flow through the air intake, then across the mesh heater, through the mesh heater, or after passing through the mesh heater, through the air outlet.

[0096] The cartridge may have first and second electrical contacts electrically connected to the mesh heater. The electrical contacts may include one or more of the following: tin, silver, gold, copper, aluminum, steel such as stainless steel, phosphor bronze, tin alloyed with antimony, tin alloyed with zirconium, tin alloyed with bismuth, or tin alloyed with other components that improve resistance to organic acids.

[0097] The electrical contacts may be directly fixed to the wires of the mesh heater. The electrical contacts may be positioned between the wires and the porous ceramic body. For example, the contacts may be formed from tin or silver, which is plated onto the porous ceramic body or otherwise attached to the porous ceramic body. The contacts may be more easily coupled to the wires than to the porous ceramic body. The electrical contacts may be integrated with the wires. For example, the mesh heater may be formed by etching a conductive sheet to provide multiple wires between two electrical contacts.

[0098] The electrical contacts may be configured to form an electrical connection with the corresponding electrical contacts on the aerosol generator when the cartridge is connected to the device.

[0099] According to a third embodiment of this disclosure, an aerosol generating system is provided comprising an aerosol generator and a cartridge. The cartridge may be a cartridge according to the first embodiment. The cartridge may be a cartridge according to the second embodiment.

[0100] The aerosol generator may be configured to be connected to a cartridge. For example, the aerosol generator may be configured to be connected to and disconnected from a cartridge. The aerosol generator may be connected to and disconnected from a cartridge via a snap-fit ​​connection, corresponding threads, or any other suitable means. The aerosol generator may be configured to receive at least a portion of a cartridge. For example, the aerosol generator may include a chamber configured to receive at least a portion of a cartridge.

[0101] The aerosol generator may be equipped with an air intake. The aerosol generator may be equipped with an air outlet. The air outlet of the aerosol generator may be in fluid communication with the air intake of the cartridge.

[0102] The aerosol generator may be equipped with a power source such as a battery. When the cartridge is connected to the device, the power source may be configured to supply power to a mesh heater, for example, to resistively heat the mesh heater.

[0103] The power supply may be electrically connected to the first and second electrical contacts of the device. These first and second electrical contacts may be configured to form an electrical connection with the corresponding electrical contacts on the cartridge when the cartridge is connected to the device. The mesh heater may be configured to be resistively heated. The mesh heater may be a wire or an electrical resistance track connected to the electrical contacts on the cartridge, or may include these. The wire or track may be heated when the power supply passes current through the wire or track. Thus, when the cartridge is connected to the aerosol generator, the power supply of the aerosol generator may be configured to supply power to the mesh heater. That is, the power supply may pass current through the mesh heater, or the wire or track of the mesh heater, and resistively heat the mesh heater.

[0104] The cartridge or aerosol generator may include an inductor, such as an induction coil. The mesh heater may be made of susceptor material or may contain susceptor material.

[0105] The power supply may be configured to pass current through an inductor so that the inductor generates a fluctuating electromagnetic field. This can then generate eddy currents and hysteresis losses within the susceptor material. This can heat the susceptor material. Thus, the power supply and inductor may be configured to inductively heat the mesh heater.

[0106] The susceptor material may be, or include, any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. Preferred susceptor materials may be heated to temperatures above 100, 150, 200, or 250 degrees Celsius. Preferred susceptor materials may include metals or carbon. Preferred susceptor materials may include ferromagnetic materials, such as ferrite iron, or ferromagnetic steel or stainless steel. A suitable susceptor element may be aluminum, or may include aluminum. Preferred susceptor materials may include, or be formed from, 400 series stainless steel, such as grade 410, or grade 420, or grade 430 stainless steel. Different materials dissipate different amounts of energy when positioned in an electromagnetic field having similar values ​​of frequency and magnetic field strength. Thus, parameters of the susceptor material, such as the type and size of the material, may be modified to provide the desired power dissipation in known electromagnetic fields.

[0107] The inductor can be an induction coil. The induction coil may be located inside the cartridge. The induction coil may be arranged around the mesh heater. For example, the induction coil may be spirally arranged around the mesh heater. The inductor may be electrically connected to electrical contacts on the cartridge. When the cartridge is connected to the aerosol generator, these electrical contacts may be electrically connected to corresponding electrical contacts on the device that are electrically connected to the device's power supply. Thus, when the cartridge is connected to the device, the device's power supply may be configured to pass current through the inductor to generate a fluctuating electromagnetic field, thereby heating the susceptor material of the mesh heater.

[0108] An inductor, such as an induction coil, may be located within the aerosol generator. The inductor may be electrically connected to a power supply. The aerosol generator may include a chamber for receiving at least a portion of the cartridge. The induction coil may be arranged around at least a portion of this chamber. For example, the induction coil may be spirally arranged around at least a portion of the chamber. Therefore, when the cartridge, or a portion thereof, is received within the chamber, the induction coil may be arranged around the mesh heater, or spirally arranged around the mesh heater. Thus, when the cartridge is connected to the device, the power supply of the device may be configured to pass current through the inductor to generate a fluctuating electromagnetic field, thereby heating the susceptor material of the mesh heater.

[0109] The aerosol generator may include a controller. The controller may be configured to control the power supply from the power source. Thus, the controller can control the heating of the mesh heater.

[0110] A non-exclusive list of non-limiting embodiments is provided below. These embodiments are described in the sections. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, forms, or aspects described herein.

[0111] A. A cartridge for use in an aerosol generating system, the cartridge is A porous ceramic body having a void ratio of 30% to 65%, A cartridge comprising a mesh heater that engages with a porous ceramic body, the mesh heater having a plurality of openings, each opening having dimensions of 50 microns to 200 microns. B. The cartridge described in item A, in which, when in use, the liquid aerosol-forming substrate is drawn out from the porous ceramic body into the opening of the mesh heater. C. When in use, the liquid aerosol-forming substrate is drawn into the opening of the mesh heater by capillary action, as described in item A or B. D. The mesh heater is a cartridge as described in any of sections A to C, which is substantially flat or substantially planar. E. The cartridge described in item D, wherein, when in use, the direction of movement of the bulk liquid aerosol-forming substrate is substantially perpendicular to the plane of the mesh heater. F. A cartridge according to any of items A to E, wherein the mesh heater or a portion thereof is substantially parallel to the first plane of the porous ceramic body. G. The mesh heater is a cartridge as described in item F, which is attached to the first surface of a porous ceramic body. H. The cartridge according to item F or G, wherein the porous ceramic body includes a second surface substantially opposite to the first surface. I. During use, the liquid aerosol-forming substrate moves in the direction from the second surface to the first surface, for example, from the second surface to the first surface, as described in item H. J. The cartridge is the cartridge according to any one of items A to I, comprising a liquid aerosol-forming substrate storage component for storing a liquid aerosol-forming substrate. K. The liquid aerosol-forming substrate storage component is a cartridge as described in item J, which is in fluid communication with a porous ceramic body. The cartridge according to item H or I, comprising a liquid aerosol-forming substrate storage component for storing a liquid aerosol-forming substrate, wherein the liquid aerosol-forming substrate storage component is in fluid communication with a second surface of a porous ceramic body. M. Mesh heaters are cartridges containing metal, as described in any of sections A to L. N. The mesh heater is a cartridge containing steel, as described in item M. O. A mesh heater is a cartridge containing a network of wires, as described in any of sections A to N. P. The mesh heater is a cartridge containing woven wire mesh, as described in item O. Q. The mesh heater is a hybrid mesh heater comprising a network of wires and fibers, wherein the fibers have a different material composition from the wires, as described in any of sections A to P. R. Wire is a cartridge containing metal, as described in item Q. S. Wire is a cartridge containing steel, as described in item R. T. The wire is substantially perpendicular to the fiber, as described in any of items Q to S of the cartridge. U. Mesh heaters are cartridges as described in any of items Q to T, including woven wire and fiber mesh. V. The fiber is a cartridge as described in any of items Q to U, having an average diameter of 80% to 120% of the average wire diameter. W. The fibers have an average diameter of at least 10 microns, as described in any of items Q to V of the cartridge. X. The fibers are those of the cartridge described in any of items Q to W, having an average diameter of less than 100 microns. Y. The fiber is glass fiber, as described in any of items Q to X of the cartridge. Z. The fiber is rayon fiber, as described in any of items Q to X of the cartridge. AA. The wire has an average diameter of at least 10 microns, as described in any of the items O to Z of the cartridge. AB. The wire is a cartridge as described in any of items O to AA, having an average diameter of less than 100 microns. The AC mesh heater is a cartridge, including the sheet, as described in any of sections A to N. AD. The sheet is made of metal, as described in item AC of the cartridge. AE. The sheet includes multiple openings, as described in section AC or AD of the cartridge. AF. The sheet is perforated, as described in any of sections AC to AE. AG. The sheet is a cartridge as described in any of sections AC to AF, including a heating track placed on it. AH. The mesh heater is substantially flat or substantially planar, and the thickness of the mesh heater is greater than 30 microns, as described in any of sections A to AG. AI. A mesh heater is a cartridge according to any of items A to AH, which engages with a porous ceramic body over substantially the entire surface of the mesh heater. AJ. The mesh heater is a cartridge described in section AI, which is in contact with a porous ceramic body over substantially the entire surface of the mesh heater. AK. A porous ceramic body comprising one or more of steatite, alumina, and zirconia, as described in any of sections A to AJ. AL. A porous ceramic body containing pores having an average pore size of 2.5 microns to 40 microns, as described in any of items A to AK. AM. A porous ceramic body, including a first part and a projection, as described in any of sections A to AL. AN. The protrusion is located around the first part, as described in item AM of the cartridge. AO. The projection extends substantially around the entire periphery of the first part, as described in item AN of the cartridge. AP. The projection extends substantially perpendicularly from the surface of the first part, as described in any of sections AM to AO of the cartridge. AQ. A cartridge as described in any of sections AM to AP, wherein the first part comprises a length, a width perpendicular to the length, and a thickness perpendicular to the length and width, and the length and width are at least twice the thickness. AR. The first part is a cartridge as described in any of sections AM to AP, having a substantially circular cross-section. AS. The first part has a diameter and a thickness, the cartridge as described in item AR, wherein the diameter is at least twice the thickness. AT. The first part is a cartridge as described in any of items AM to AS, having a thickness of at least 1.5 mm. AU. The first part is a cartridge as described in any of items AM to AT, having a thickness of less than 6 mm. AV. The projection has a width of at least 1.5 mm, as described in any of items AM to AU of the cartridge. AW. The protrusion has a width of less than 6 mm and is a cartridge as described in any of items AM to AV. AX. A porous ceramic body, including channels extending through it, as described in any of sections A to AW. AY. The first part of the porous ceramic body includes a channel extending through it, as described in any of sections AM to AW. The AZ channel extends substantially in the thickness direction of the first part, as described in item AY of the cartridge. BA. The mesh heater is substantially flat or substantially planar, and the channels extend substantially perpendicular to the plane of the mesh heater, as described in section AX, AY, or AZ of the cartridge. The BB channel is a cartridge as described in any of items AX to BA, having a diameter of at least 300 microns. BC. The channel is a cartridge as described in any of items AX to BB, having a diameter of less than 800 microns. BD. A mesh heater is a cartridge described in any of sections A to BC, which is attached to a porous ceramic body by soldering. BE. The solder points are made of silver or tin, as specified in item BD of the cartridge. BF. A cartridge according to any of items A to BE, comprising a metal segment located between a porous ceramic body and a mesh heater. The BG. Mesh heater is a cartridge described in section BF, in which metal segments are bonded to a porous ceramic body. BH. The metal segment contains silver or tin, as described in section BF or BG of the cartridge. BI. The mesh heater is a cartridge as described in any of items A to BH, located between the porous ceramic body and the second ceramic coating layer. The cartridge described in item BI, wherein the second ceramic coating layer comprises ceramic material, and the porous ceramic body comprises ceramic material. BK. The second ceramic coating layer has a thickness of less than 5000 microns, as described in item BI or BJ. BL. The cartridge according to item BI, BJ, or BK, wherein the second ceramic coating layer has a thickness of at least 10 microns. BM. The second ceramic coating layer covers less than 80% of the surface of the mesh heater, as described in any of sections BI to BL of the cartridge. BN. The second coating layer of the cartridge is in contact with the mesh heater, as described in any of sections BI to BM. The BO. Mesh heater is a cartridge described in any of sections BI to BN, which is attached to a porous ceramic body by a second ceramic coating layer. The BP cartridge is a cartridge described in any of sections A to B, which has electrical contacts electrically connected to the mesh heater. BQ. Electrical contacts include tin, silver, gold, copper, aluminum, stainless steel, phosphor bronze, tin alloyed with antimony, tin alloyed with zirconium, tin alloyed with bismuth, or tin alloyed with other components to improve resistance to organic acids, as described in item BP. BR. An aerosol generating system comprising an aerosol generator and a cartridge as described in any of sections A to BQ. BS. The aerosol generating device is configured to be connected to a cartridge, as described in item BR. BT. The aerosol generating system according to item BR or BS, comprising a power supply configured to supply power to a mesh heater to resistively heat the mesh heater. BU. The aerosol generator comprises a power supply, and the cartridge or aerosol generator includes an inductor, and the power supply and inductor are configured to inductively heat a mesh heater, as described in section BR or BS.

[0112] Here, we will further describe the examples with reference to the figures. [Brief explanation of the drawing]

[0113] [Figure 1] Figure 1 shows a cross-sectional view of an aerosol generation system incorporating a cartridge having the first heater assembly. [Figure 2] Figure 2 shows a cross-sectional view of the cartridge incorporating the first heater assembly. [Figure 3] Figure 3 shows a perspective view of the first heater assembly. [Figure 4] Figure 4 shows a cross-sectional view of the first heater assembly. [Figure 5] Figure 5 shows a perspective view of the second heater assembly. [Figure 6] Figure 6 shows a cross-sectional view of the second heater assembly. [Figure 7] Figure 7 shows a perspective view of the third heater assembly. [Figure 8] Figure 8 shows a cross-sectional view of the third heater assembly. [Figure 9] Figure 9 shows a cross-sectional view of an aerosol generation system incorporating a cartridge with a third heater assembly. [Modes for carrying out the invention]

[0114] Figure 1 shows a cross-sectional view of the aerosol generating system 100. The aerosol generating system 100 comprises an aerosol generator 150 and a cartridge 200. In this embodiment, the aerosol generating system 100 is an electrically operated smoking system.

[0115] The aerosol generator 150 is portable and has a size comparable to a conventional cigar or cigarette. The device 150 includes a battery 152, such as a lithium iron phosphate battery, and a controller 154 electrically connected to the battery 152. The device 150 also includes two electrical contacts 156 and 158 electrically connected to the battery 152. This electrical connection is wired and is not shown in Figure 1.

[0116] The cartridge 200 comprises an air intake 202, an air outlet 204, and a first heater assembly 300. The air intake 202 is in fluid communication with the air outlet 204. The heater assembly 300 is positioned downstream of the air intake 202 and upstream of the air outlet 204. The heater assembly 300 includes a porous ceramic body 302 and a substantially planar mesh heater 304 that engages with the porous ceramic body 302.

[0117] The mesh heater 304 includes a hybrid mesh comprising stainless steel wire 306 and glass fiber 308. The stainless steel wire 306 is woven with the glass fiber 308 and is substantially perpendicular to the glass fiber 308. Thus, the mesh heater 304 includes a woven hybrid mesh. The mesh heater 304 is attached to a porous ceramic body 302 by two solder points 310, 312. In this embodiment, the solder points 310, 312 are formed from tin, but silver or another suitable material may be used. Each of these solder points 310, 312 is electrically connected to electrical contacts 214, 216 on the cartridge. This electrical connection is a wired connection and is not shown in Figure 1. Through this electrical connection, the stainless steel wire 306 is electrically connected to the electrical contacts 214, 216.

[0118] The porous ceramic body 302 contains numerous pores. The liquid aerosol-forming substrate is held within the pores of the porous ceramic body 302.

[0119] In Figure 1, the aerosol generator 150 is connected to the cartridge 200. In this embodiment, the cartridge 200 is connected to the aerosol generator 150 via projections 206, 208 that form snap-fit ​​connections with corresponding openings 160, 162 on the aerosol generator 150.

[0120] The cartridge 200 further comprises a liquid aerosol-forming substrate storage component 288 that is in fluid communication with the porous ceramic body 302. The liquid aerosol-forming substrate storage component 288 is in contact with the first portion 320 of the porous ceramic body 302. The liquid aerosol-forming substrate storage component 1008 may be bonded to the porous ceramic body 302 with an adhesive, or held in place by friction, or held in place by other suitable means. In this embodiment, the liquid aerosol-forming substrate storage component 288 is a capillary material having a fibrous or spongy structure, but in other embodiments, a storage section or tank of the liquid aerosol-forming substrate may be used. The capillary material is formed from polyester, but any suitable material may be used. The capillary material is immersed in the aerosol-forming substrate. Thus, in Figure 1, the aerosol-forming substrate is stored in the pores of the porous ceramic body 302 and in the liquid aerosol-forming substrate storage component 288.

[0121] During use, the user inhales smoke from the air outlet 204 of the cartridge 200. Simultaneously, the user presses a button (not shown) on the aerosol generator 150. Pressing this button sends a signal to the controller 154, which in turn supplies power from the battery 152 to the mesh heater 302 via the device's electrical contacts 156, 158 and the cartridge's electrical contacts 214, 216. This causes current to flow through the stainless steel wire 306 of the mesh heater 304, thereby resistively heating the stainless steel wire 306 and heating the mesh heater 304 as a whole. In other embodiments, an airflow sensor or pressure sensor is located inside the cartridge 200 and electrically connected to the controller 154. The airflow sensor or pressure sensor detects that the user is inhaling smoke from the air outlet 204 of the cartridge 200 and sends a signal to the controller 154 to supply power to the mesh heater 304. Thus, in these embodiments, the user does not need to press a button to heat the mesh heater 304. The liquid aerosol-forming substrate held within the pores of the porous ceramic body 302 is drawn out into the opening of the mesh heater 304 by capillary action. The mesh heater 304 heats this liquid aerosol-forming substrate, causing it to vaporize.

[0122] As the liquid aerosol-forming substrate is drawn out of the porous ceramic body 302 into the opening of the mesh heater 304 and vaporized, the liquid aerosol-forming substrate is also drawn out of the liquid aerosol-forming substrate storage component 288 into the porous ceramic body 302. Therefore, the user may be able to generate more aerosol than if the liquid aerosol-forming substrate storage component 288 were not present.

[0123] As the user inhales smoke from the air outlet 204 of the cartridge 200, air is drawn into the air intake 202. This air then moves around the heater assembly 300 and towards the air outlet 204. This airflow entrains vapor formed by heating the liquid aerosol-forming substrate by the mesh heater 304. This entrained vapor is then cooled and condensed to form an aerosol. This aerosol is then delivered to the user through the air outlet 204.

[0124] Figure 2 shows a cross-sectional view of the cartridge 200 incorporating the first embodiment of the heater assembly 300. In Figure 2, the cartridge 200 is no longer connected to the aerosol generator 150.

[0125] Figures 3 and 4 show perspective and cross-sectional views, respectively, of the first heater assembly 300. Figure 3 also shows the liquid aerosol-forming substrate storage component 288. The heater assembly 300 includes a porous ceramic body 302 and a mesh heater 304. The mesh heater 304 is in contact with the porous ceramic body 302 over substantially the entire surface of the mesh heater 304.

[0126] The stainless steel wires 306 and glass fibers 308 of the mesh heater 304 are woven together. Thus, the mesh heater 304 contains a woven hybrid mesh. The stainless steel wires 306 and glass fibers 308 of the mesh heater 304 have a diameter of approximately 17 microns. The thickness of the mesh heater 304 is approximately 51 microns. In Figure 3, the openings 309 of the mesh heater are visible. Each of these openings 309 has dimensions of approximately 70 microns. In this embodiment, the openings 309 have a substantially square cross-section, and the dimensions are equal to the length of the sides of the square cross-section.

[0127] The porous ceramic body 302 is formed entirely from alumina. The porous ceramic body 302 contains pores with pore sizes ranging from 2.5 microns to 40 microns. The average pore size is approximately 10 microns. The porosity of the porous ceramic body 302 is approximately 40%.

[0128] The porous ceramic body 302 includes a first portion 320 and a projection 322. The first portion 320 has a substantially circular cross-section. This circular cross-section has a diameter of about 15 mm. The first portion 320 has a thickness of about 2 mm.

[0129] The projection 322 has a substantially annular or ring-shaped cross-section. The projection 322 is located around the first portion 320 and extends substantially around the entire periphery of the first portion 320. The projection 322 extends substantially perpendicularly from the surface of the first portion 320 by about 10 mm. The projection 322 has a width of about 2 mm. The width of the substantially annular projection is the difference between the outer diameter and the inner diameter of the annular portion.

[0130] The first portion 320 of the porous ceramic body 302 includes a channel 314 extending through it. The channel 314 extends substantially in the thickness direction of the first portion 320. Thus, the channel 314 extends substantially perpendicular to the plane of the mesh heater 304. The channel 314 has a diameter of about 500 microns.

[0131] Figures 5 and 6 show perspective and cross-sectional views, respectively, of the second heater assembly 500. Figure 5 also shows the liquid aerosol-forming substrate storage component 288.

[0132] The second heater assembly 500 includes a porous ceramic body 502 and a mesh heater 504. The porous ceramic body 502 is identical to the porous ceramic body 302 of the first heater assembly 300.

[0133] The mesh heater 504 includes a hybrid mesh comprising stainless steel wire 506 and rayon fibers 508. The stainless steel wire 506 is woven with the rayon fibers 508 and is substantially perpendicular to the rayon fibers 508. The mesh heater 504 engages with a porous ceramic body 502. Specifically, the mesh heater 504 is attached to the porous ceramic body 502. To attach the mesh heater 504 to the porous ceramic body 502, two metal segments 510, 512 are applied to the porous ceramic body 502. In this embodiment, the metal segments 510, 512 are formed from tin, but silver or other suitable materials may be used. The mesh heater 504 is then positioned such that the metal segments 510, 512 are between the porous ceramic body 502 and the mesh heater 504. The mesh heater 504 is then forced into the metal segments 510, 512 toward the porous ceramic body 502. Metal segments 510 and 512 bond the porous ceramic body 502 to the mesh heater 504. In some embodiments, the metal segments cover the mesh heater. In some embodiments, heat is applied while the mesh heater is forced toward the porous ceramic body.

[0134] The second heater assembly 500 also includes two electrodes 511, 513. These electrodes are made of tin and are in contact with several stainless steel wires 506 and rayon fibers 508 of the mesh heater 504. When the second heater assembly 500 replaces the first heater assembly 300 in the cartridge 200 shown in Figures 1 and 2, the electrodes 511, 513 are electrically connected to electrical contacts 214, 216 on the cartridge 200, respectively. This electrical connection is a wired connection and is not shown in Figures 1 or 2. The stainless steel wires 506 are electrically connected to electrical contacts 214, 216 through this electrical connection.

[0135] The stainless steel wire 506 and rayon fiber 508 of the mesh heater 504 have a diameter of approximately 17 microns. The thickness of the mesh heater 504 is approximately 51 microns. In Figure 5, the openings 509 of the mesh heater are visible. Each of these openings has dimensions of approximately 70 microns. In this embodiment, the openings 509 have a substantially square cross-section, and the dimensions are equal to the length of the sides of the square cross-section.

[0136] The mesh heater 504 is in contact with the porous ceramic body 502 over substantially the entire surface of the mesh heater 504. During use, the liquid aerosol-forming substrate held within the pores of the porous ceramic body 502 is drawn out into the opening 509 of the mesh heater 504.

[0137] When in use, the second heater assembly 500 functions in much the same way as the first heater assembly 300. The second heater assembly 500 can replace the first heater assembly 300 shown in the aerosol generating system of Figure 1. In this case, the system 100 functions similarly, but power is supplied to the mesh heater 504 of the second heater assembly 500 through the tin electrodes 511, 513 (rather than through the solder points 310, 312 of the first heater assembly 300).

[0138] Figures 7 and 8 show perspective and cross-sectional views of the third heater assembly 700. Figure 7 also shows the liquid aerosol-forming substrate storage component 1008.

[0139] The third heater assembly 700 includes a porous ceramic body 702 and a mesh heater 704. The porous ceramic body 702 is identical to the porous ceramic body of the first heater assembly 302.

[0140] The mesh heater 704 includes a perforated stainless steel plate 706. The stainless steel plate 706 of the mesh heater 704 is an effective susceptor material. Therefore, the plate 706 acts as a susceptor.

[0141] To attach plate 706 to the porous ceramic body 702, plate 706 is positioned in contact with the porous ceramic body 702. A coating layer 708 of ceramic paste is then applied over plate 706. Part of the paste is located on plate 706, and part of the paste is located on the porous ceramic body 702. The paste applied to the porous ceramic body 702 may be applied beyond the periphery of plate 706, through the opening 709 of plate 706, or both, as in this embodiment. At least a portion of plate 706 is located between the coating layer 708 and the porous ceramic body 702. The coating layer 708 is then sintered. The porous ceramic body 702 is sintered at the same time. In this embodiment, the coating layer 708 is formed from the same alumina as the alumina of the porous ceramic body 702. The coating layer 708 adheres the porous ceramic body 702 to plate 706.

[0142] The perforations in plate 706 form openings 709 having a substantially circular cross-section. Figure 7 shows the openings 709 of the mesh heater 704. Each of these openings has dimensions of approximately 75 microns. In this embodiment, the openings 709 have a substantially circular cross-section, and their dimensions are equal to the diameter of the circular cross-section.

[0143] The mesh heater 704 is in contact with the porous ceramic body 702 over substantially the entire surface of the mesh heater 704.

[0144] Figure 9 shows a cross-sectional view of the aerosol generating system 900. The aerosol generating system 900 comprises a cartridge 1000 having an aerosol generator 950 and a third heater assembly 700. In this embodiment, the aerosol generating system 900 is an electrically operated smoking system.

[0145] The aerosol generator 950 is portable and has a size comparable to a conventional cigar or cigarette. The device 950 includes a battery 952, such as a lithium iron phosphate battery, and a controller 954 electrically connected to the battery 952. The device 950 also includes an induction coil 956 electrically connected to the battery 952. The device 950 also includes an air intake 958 and an air outlet 960 that is in fluid communication with the air intake 958.

[0146] The cartridge 1000 comprises an air intake 1002, an air outlet 1004, and a third heater assembly 700. The air intake 1002 is in fluid communication with the air outlet 1004. The heater assembly 700 is positioned downstream of the air intake 1002 and upstream of the air outlet 1004. As shown in Figure 9, when the cartridge 1000 is connected to the aerosol generator 950, the air outlet 960 of the device 950 is adjacent to the air intake 1002 of the cartridge 1000. Therefore, during use, when a user inhales smoke from the air outlet 1004 of the cartridge 1000, the air passes through the air intake 958 of the device 950, then through the air outlet 960 of the device 950, then through the air intake 1002 of the cartridge 1000, then through the heater assembly 700, and then out of the air outlet 1004 of the cartridge 1000.

[0147] In Figure 9, the cartridge 1000 is connected to the aerosol generator 950 by engaging the threads 1006 of the cartridge 1000 with the corresponding threads 962 of the aerosol generator 950.

[0148] The cartridge 1000 further comprises a liquid aerosol-forming substrate storage component 1008 that is in fluid communication with the porous ceramic body 702. The liquid aerosol-forming substrate storage component 1008 is in contact with the first portion 720 of the porous ceramic body 702. The liquid aerosol-forming substrate storage component 1008 may be bonded to the porous ceramic body 702 with an adhesive, or held in place by friction, or held in place by other suitable means. The liquid aerosol-forming substrate storage component 1008 in this embodiment is a capillary material having a fibrous or spongy structure. The capillary material is formed from polyester, but any suitable material may be used. The capillary material is immersed in the aerosol-forming substrate. Thus, in Figure 9, the aerosol-forming substrate is stored in the pores of the porous ceramic body 702 and in the liquid aerosol-forming substrate storage component 1008.

[0149] During use, the user draws smoke from the air outlet 1004 of the cartridge 1000. Simultaneously, the user presses a button (not shown) on the aerosol generator 950. Pressing this button sends a signal to the controller 954, which in turn causes the battery 952 to supply a high-frequency current to the induction coil 956. This causes the induction coil to generate a fluctuating electromagnetic field. The mesh heater 704 is positioned within this magnetic field. Thus, this fluctuating electromagnetic field generates eddy currents and hysteresis losses within the stainless steel plate 706, which acts as a susceptor heating element for the cartridge 1000. Consequently, the plate 706 is inductively heated. In other embodiments, an airflow sensor or pressure sensor is located within the device 950 and electrically connected to the controller 954. The airflow sensor or pressure sensor detects that the user is drawing smoke from the air outlet 1004 of the cartridge 1000 and sends a signal to the controller 954 to power the mesh heater 704. Therefore, in these embodiments, the user does not need to press a button to heat the mesh heater 704. The liquid aerosol-forming substrate held in the pores of the porous ceramic body 702 is drawn out into the openings of the plate 706 of the mesh heater 704 by capillary action. The mesh heater 704 heats this liquid aerosol-forming substrate, vaporizing it.

[0150] As the user inhales smoke from the air outlet 1004 of cartridge 1000, air is drawn into the air intake 958 of device 950, then through the air outlet 960 of device 950, and then through the air intake 1002 of cartridge 1000. This air then moves around heater assembly 700 and toward air outlet 1004. This airflow entrains vapor formed by heating of the liquid aerosol-forming substrate by mesh heater 704. This entrained vapor is then cooled and condensed to form an aerosol. This aerosol is then delivered to the user via air outlet 1004.

[0151] As the liquid aerosol-forming substrate is drawn out of the porous ceramic body 702 into the opening 709 of the mesh heater 704 and vaporized, the liquid aerosol-forming substrate is also drawn out of the liquid aerosol-forming substrate storage component 1008 into the porous ceramic body 702. Therefore, the user may be able to generate more aerosol than when the liquid aerosol-forming substrate storage component 1008 is not present.

[0152] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures representing amounts, quantities, percentages, etc., should be understood in all cases as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points, and any intermediate ranges between them, which may or may not be specifically enumerated herein. Therefore, in this context, the figure A is understood as A ± 10%.

Claims

1. 1. A cartridge for use in an aerosol generation system, said cartridge comprising: a porous ceramic body having a porosity of 30% to 65%; and a mesh heater engaged with the porous ceramic body, the mesh heater including a plurality of openings, each opening having a dimension of 50 microns to 200 microns; The cartridge, wherein the mesh heater is a hybrid mesh heater comprising a network of wires and fibers, the fibers having a different material composition than the wires.

2. 10. The cartridge of claim 1, wherein, in use, a liquid aerosol-forming substrate is drawn from the porous ceramic body into the openings in the mesh heater by capillary action.

3. 3. The cartridge of claim 1, wherein the fibers comprise one or both of glass fibers and rayon fibers.

4. The cartridge of any preceding claim, wherein the mesh heater engages the porous ceramic body over substantially the entire surface of the mesh heater.

5. The cartridge of claim 4 , wherein the mesh heater contacts the porous ceramic body over substantially the entire surface of the mesh heater.

6. A cartridge according to any preceding claim, wherein the porous ceramic body comprises pores having an average pore size of from 2.5 microns to 40 microns.

7. The cartridge of any preceding claim, wherein the porous ceramic body comprises a first portion and a protrusion.

8. The cartridge of claim 7 , wherein the protrusion is located on the periphery of the first portion and extends around substantially the entire periphery of the first portion.

9. A cartridge according to any preceding claim, wherein the porous ceramic body includes channels extending therethrough, the channels having a diameter of between 300 microns and 800 microns.

10. A cartridge according to any preceding claim, comprising a metal segment located between the porous ceramic body and the mesh heater.

11. A cartridge according to any preceding claim, wherein the mesh heater is located between the porous ceramic body and a second ceramic coating layer.

12. The cartridge of claim 11 , wherein the mesh heater is attached to the porous ceramic body by the coating layer of the second ceramic.

13. An aerosol generation system comprising an aerosol generating device and a cartridge according to any one of claims 1 to 12.

14. 14. The aerosol generation system of claim 13, wherein the aerosol generation device comprises a power supply configured to provide power to the mesh heater to resistively heat the mesh heater.

15. 14. The aerosol generation system of claim 13, wherein the aerosol generation device comprises a power source, the cartridge or the aerosol generation device comprises an inductor, and the power source and the inductor are configured to inductively heat the mesh heater.

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