Heater Assembly

Abstract

A heater assembly (300) for use in an aerosol generation system (100) is provided. The heater assembly (300) includes a liquid aerosol-forming substrate storage component (302) and a heating element (304). The heating element (304) includes a first portion (306) and a second portion (308). The first portion (306) of the heating element (304) is embedded in the liquid aerosol-forming substrate storage component (302), and the second portion (308) of the heating element (304) is not embedded in the liquid aerosol-forming substrate storage component (302). An aerosol generation system (100) including the heater assembly (300) is also provided.

Description

[Technical field]

[0001] The present disclosure relates to a heater assembly. In particular, the present disclosure relates to a heater assembly for use in an aerosol generation system. The present disclosure also relates to a method of assembling the heater assembly, a cartridge including the heater assembly, and an aerosol generation system including the heater assembly. [Background technology]

[0002] In many known aerosol generating systems, a liquid aerosol-forming substrate is heated and vaporized into a vapor. The vapor is cooled and condensed to form an aerosol. In some aerosol generating systems, such as electrically heated smoking systems, this aerosol is then inhaled by a user.

[0003] Typically, the liquid aerosol-forming substrate contains several compounds that are vaporized when heated. These compounds may have different boiling points. For example, the liquid aerosol-forming substrate may contain nicotine (which has a boiling point of about 247 degrees Celsius at atmospheric pressure) and glycerol (which has a boiling point of about 290 degrees Celsius at atmospheric pressure).

[0004] When a liquid aerosol-forming substrate having compounds with different boiling points is heated, the compound with the lower boiling point may be vaporized before the compound with the higher boiling point. Alternatively, or additionally, the compound with the lower boiling point may be vaporized at a faster rate than the compound with the higher boiling point.

[0005] This may be undesirable because the interaction and combination between different compounds may be limited.For example, the liquid aerosol-forming substrate may include a nicotine compound and an organic acid compound, and these compounds have different boiling points. Both of these compounds may be vaporized. The nicotine in the liquid aerosol-forming substrate may form free base nicotine when vaporized. However, it may be desirable to generate an aerosol using a nicotine salt rather than free base nicotine. To form this nicotine salt, the free base nicotine may be protonated by the vaporized organic acid. However, this protonation may be limited if the organic acid is not vaporized until after nicotine is vaporized, or vaporizes slower than necessary to protonate a suitable proportion of the free base nicotine.

[0006] Furthermore, vaporizing some compounds of the aerosol-forming substrate more quickly than others can undesirably change the properties of the generated aerosol over time, for example, during the course of a puff in the aerosol-generating system. This is because, early in the puff, when the heating element is activated and the temperature rises, the liquid aerosol-forming substrate close to the heating element may reach a first temperature at which a first compound with a lower boiling point is vaporized, but a second compound with a higher boiling point is not vaporized. Then, later in the puff, the liquid aerosol-forming substrate close to the heating element may reach a second temperature at which a second compound with a higher boiling point is vaporized. However, at this point, most of the first compound in the liquid aerosol-forming substrate close to the heating element may already be vaporized. Thus, early in the puff, the generated aerosol may contain a greater proportion of the first compound, and later in the puff, the generated aerosol may contain a greater proportion of the second compound.

[0007] Alternatively, or in addition, the properties of the generated aerosol may change over the course of several puffs. This may occur if the compounds of the liquid aerosol-forming substrate are not vaporized at an appropriate rate. For example, the liquid aerosol-forming substrate may contain X weight percent of a first compound and Y weight percent of a second compound. If the liquid aerosol-forming substrate is not vaporized to produce a vapor containing a mass ratio of X to Y of the first compound to the second compound, the composition of the liquid aerosol-forming substrate may change as the vapor is generated. This may then result in a change in the properties of the aerosol generated by the liquid aerosol-forming substrate. Summary of the Invention

[0008] It is an object of the present invention to control the vaporization of various compounds of a liquid aerosol-forming substrate, where these compounds have different boiling points.

[0009] According to an aspect of the present disclosure, a heater assembly is provided. The heater assembly may be suitable for use in an aerosol generating system. The heater assembly may include a liquid aerosol-forming substrate storage component. The heating element may include a first portion. The heating element may include a second portion. The first portion of the heating element may be embedded in the liquid aerosol-forming substrate storage component. The second portion of the heating element may not be embedded in the liquid aerosol-forming substrate storage component.

[0010] The heater assembly may provide regions of higher and lower temperatures in the liquid aerosol-forming substrate storage component. Alternatively, or in addition, the heater assembly may provide regions in the liquid aerosol-forming substrate storage component where the temperature increases at a faster rate and regions where the temperature increases at a slower rate.

[0011] Advantageously, the heater assembly may improve control of vaporization of different compounds of the liquid aerosol-forming substrate. The heater assembly may simultaneously vaporize liquid aerosol-forming substrate compounds having higher and lower boiling points at a desired rate. The heater assembly may vaporize liquid aerosol-forming substrate compounds having higher and lower boiling points in a more preferred ratio. The heater assembly may provide for generation of an aerosol having a more desirable composition. The heater assembly may provide for more consistent generation of an aerosol having desirable properties.

[0012] The heating element may comprise a third portion and a fourth portion. The third portion of the heating element may be embedded in the liquid aerosol-forming substrate storage component. The fourth portion may not be embedded in the liquid aerosol-forming substrate storage component.

[0013] Advantageously, this can create more regions of higher temperature and more regions of lower temperature in the liquid aerosol-forming substrate storage component. Alternatively, or in addition, this can provide more regions of the liquid aerosol-forming substrate storage component that increase in temperature at a faster rate and more regions of the liquid aerosol-forming substrate storage component that increase in temperature at a slower rate. This can result in liquid aerosol-forming substrate compounds with higher and lower boiling points that are simultaneously vaporized at a desired rate.

[0014] The second portion of the heating element may extend between the first portion and the third portion, i.e., the second portion of the heating element may connect the first portion of the heating element to the third portion of the heating element, and the third portion may be connected to the first portion only via the second portion.

[0015] The third portion of the heating element may extend between the second portion and the fourth portion, i.e., the third portion of the heating element may connect the second portion of the heating element to the fourth portion of the heating element, and the fourth portion may be connected to the second portion only via the third portion.

[0016] The heating element, or one, two or more, or all of the first, second, third, and fourth portions may comprise an electrically resistive material. The heater assembly may be configured such that, in use, an electric current is passed through said portion or portions. This may resistively heat said portion or portions. In this manner, said portion or portions may be configured to be resistively heated.

[0017] One, two or more, or all of the first, second, third, and fourth portions of the heating element may be formed from the same material.

[0018] One, two or more, or all of the first, second, third, and fourth portions of the heating element may have substantially the same electrical resistivity (measured in ohm-meters). For example, the first and second portions may have the same electrical resistivity. Alternatively, or additionally, the third and fourth portions of the heating element may have the same electrical resistivity. As used herein, the term "substantially the same electrical resistivity" is used to mean within 20, 10, or 5 percent of a given electrical resistivity.

[0019] The heating element, or one or more or all of the first, second, third and fourth parts of the heating element, may include or be formed from any material having suitable electrical and mechanical properties, for example, a suitable electrically resistive material. Suitable materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. Examples of suitable doped ceramics include 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, and nickel, iron, cobalt, stainless steel-based superalloys, Timetal®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation, 1999 Broadway Suite 4300, Denver Colorado. In composite materials, the electrically resistive material may be embedded in, encapsulated in, or coated with an insulating material, or vice versa, depending on the required energy transfer kinetics and external physicochemical properties. The heating element may include a metallic etched foil insulated between two layers of inert material. In that case, the inactive material may include Kapton®, a full layer polyimide or a mica foil.Kapton® is a registered trademark of EI du Pont de Nemours and Company, 1007 Market Street, Wilmington, Delaware 19898, United States of America.

[0020] The third portion and the fourth portion may be configured to be resistively heated. The third portion and the fourth portion may comprise an electrically resistive material. The first portion and the second portion may be configured to be resistively heated. The first portion and the second portion may comprise an electrically resistive material.

[0021] The heating element, or one, two or more, or all of the first, second, third and fourth portions may comprise a susceptor material, and the heater assembly may be configured such that, during use, the portion or portions are inductively heated.

[0022] For example, the heater assembly may be configured for use in an aerosol generation system that includes an inductor, such as an inductor coil. The inductor may be located within an aerosol generation device having a power source. The device may be configured to engage with the heater assembly or a cartridge that includes the heater assembly. Alternatively, the inductor may be located within a cartridge that includes the heater assembly. The cartridge may be configured to engage with an aerosol generation device having a power source.

[0023] The power source may be configured to pass an alternating current through an inductor in the cartridge, or through an inductor in the device, such that the inductor generates a varying electromagnetic field.

[0024] The alternating current may have any suitable frequency. The alternating current may be a high frequency alternating current. The term high frequency alternating current may refer to a frequency between 100 kilohertz (kHz) and 30 megahertz (MHz). If the inductor is a tubular inductor coil, the alternating current may have a frequency between 500 kilohertz (kHz) and 30 megahertz (MHz). If the inductor is a flat inductor coil, the alternating current may have a frequency between 100 kilohertz (kHz) and 1 megahertz (MHz).

[0025] The heating element, or one or more than one of the first, second, third, and fourth portions, or all of the heating element, may be located within or otherwise subjected to an electromagnetic field generated by the inductor. This may generate eddy currents and hysteresis losses in the susceptor material. This may heat the susceptor material. Thus, the power supply and the inductor may be configured to inductively heat one or more than one of the first, second, third, and fourth portions, or all of the heating element.

[0026] 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 in excess of 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. Preferred susceptor materials may include metal, or carbon, or both metal and carbon. Preferred susceptor materials may include ferromagnetic materials, such as ferritic iron, or ferromagnetic steel or stainless steel. Suitable susceptor elements may be or include one or more of graphite, molybdenum, silicon carbide, stainless steel, niobium, and 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 placed in electromagnetic fields having similar values ​​of frequency and field strength. Thus, the parameters of the susceptor material, such as material type, size, etc., may be modified to provide a desired power dissipation within a known electromagnetic field.

[0027] The third portion and the fourth portion may be configured to be inductively heated. The third portion and the fourth portion may comprise a susceptor material. The first portion and the second portion may be configured to be inductively heated. The first portion and the second portion may comprise a susceptor material.

[0028] Advantageously, in an aerosol generating system using induction heating, it is not necessary to form electrical contacts between the heater assembly and the aerosol generating device. Furthermore, the heating element may not need to be electrically bonded to other components. This may eliminate the need for solder or other bonding elements. Cartridges incorporating heater assemblies configured to be inductively heated may allow for the manufacture of simple, inexpensive, and robust cartridges. Cartridges are typically disposable items that are manufactured in much larger quantities than the aerosol generating devices they operate with. Thus, reducing the cost of the cartridges may translate into significant cost savings for manufacturers. Furthermore, induction heating may provide improved energy conversion compared to resistive heating. This is because induction heating does not have the power losses associated with electrical resistance in the connection between the resistive heating element and the power source.

[0029] The heating element may have a length, a width and a thickness. The heating element may comprise a strip of material. The strip may have a length, a width and a thickness. The width may be perpendicular to the length. The thickness may be perpendicular to the length and the width. The length may be greater than the width. The width may be greater than the thickness.

[0030] The cross-section, or cross-sectional area, of the heating element may vary. For example, the cross-section, or cross-sectional area, of the heating element may vary along the length of the heating element.

[0031] The heating element may extend between a first end and a second end. For example, the length of the heating element may extend between the first end and the second end. The heating element may have a first cross-sectional area at a first point between the first end and the second end. The heating element may have a second cross-sectional area at a second point between the first point and the second end. The heating element may have a third cross-sectional area at a third point between the second point and the second end. The first cross-sectional area and the third cross-sectional area may each be greater than or less than the second cross-sectional area. For example, the first cross-sectional area and the third cross-sectional area may be at least 10, 20, 50, 100, 200, or 500 percent greater than the second cross-sectional area, or at least 10, 20, 30, 40, 50, 60, 70, or 80 percent less than the second cross-sectional area. Thus, when observing how the cross-sectional area of ​​the heating element changes from the first end to the second end of the heating element, the cross-sectional area of ​​the heating element may decrease and then increase. Alternatively, or additionally, the cross-sectional area of ​​the heating element may increase and decrease.

[0032] Varying the cross-section, or cross-sectional area, of a heating element can result in different sections of the element reaching different temperatures at the same time. For example, in a resistive heating element, a section of the element having a smaller cross-sectional area may have a greater resistance and therefore may be resistively heated to a higher temperature.

[0033] Advantageously, this can create regions of higher and lower temperatures. Alternatively, or in addition, this can provide regions in the liquid aerosol-forming substrate storage component where the temperature increases at a faster rate and regions where the temperature increases at a slower rate. As mentioned above, this can result in liquid aerosol-forming substrate compounds where higher and lower boiling points are vaporized simultaneously at a desired rate.

[0034] The minimum cross-sectional area along the length of the heating element may be at least 10 percent less than the maximum cross-sectional area along the length of the heating element. The minimum cross-sectional area along the length of the heating element may be at least 20, 40, 60, or 80 percent less than the maximum cross-sectional area along the length of the heating element.

[0035] The minimum cross-sectional area of ​​the first portion of the heating element may be at least 10, 20, 40, 60, or 80 percent less than the maximum cross-sectional area of ​​the second or fourth portion. Alternatively, or additionally, the minimum cross-sectional area of ​​the third portion of the heating element may be at least 10, 20, 40, 60, or 80 percent less than the maximum cross-sectional area of ​​the second or fourth portion.

[0036] The width or thickness, or both the width and thickness, of the heating element may vary along the length of the heating element.

[0037] The heating element may be woven in and out of the liquid aerosol-forming substrate storage component. The heating element may comprise a strip of material woven in and out of the liquid aerosol-forming substrate storage component. The heating element or strip may be woven in and out of the liquid aerosol-forming substrate storage component along its length. Thus, when traced along the length of the heating element or strip, the heating element or strip may include alternating portions embedded in the liquid aerosol-forming substrate storage component, such as a first portion and a third portion, and portions not embedded in the liquid aerosol-forming substrate storage component, such as a second portion and a fourth portion.

[0038] Advantageously, heater assemblies that include a heating element woven into and out of a liquid aerosol-forming substrate storage component can be relatively simple to manufacture.

[0039] The heating element may include one or more of a curve, undulations, creases, and corrugations. A first portion of the heating element may include one or more of a curve, undulations, creases, and corrugations. A second portion of the heating element may include one or more of a curve, undulations, creases, and corrugations. A third portion of the heating element may include one or more of a curve, undulations, creases, and corrugations. A fourth portion of the heating element may include one or more of a curve, undulations, creases, and corrugations. A fifth portion of the heating element may include one or more of a curve, undulations, creases, and corrugations.

[0040] Advantageously, curves, undulations, folds, and corrugations in the heating element may allow for greater control of the location of the higher and lower temperature regions. Alternatively, or additionally, curves, undulations, folds, and corrugations in the heating element may allow for greater control of the temperature difference between the higher and lower temperature regions. For example, if a higher temperature is desired in a given region of the liquid aerosol-forming substrate storage component, the heating element may include undulations or corrugations in this region. This may increase the volume or surface area of ​​the heating element in this region, and therefore increase the heat transferred from the heating element to this region.

[0041] The heating element may have a first end and a second end. The length of the heating element may extend from the first end to the second end. If the heating element does not extend directly from the first end to the second end, i.e., is linear, the heating element may be considered to include one or more of a curve, an undulation, a fold, and a corrugation.

[0042] A curve may refer to a gradual change in the direction of a heating element, for example, a gradual change in the direction of a heating element between a first end and a second end. Thus, a curve may form an arc, or a "C" shape.

[0043] A fold may refer to a gradual change in the orientation of the heating element, for example, a gradual change in the orientation of the heating element between a first end and a second end. Thus, the fold may form two sides of a polygon, or a "V" shape.

[0044] The undulations may include multiple curves. For example, the undulations may refer to a step change in the orientation of the heating element in a first direction, followed by a step change in the orientation of the heating element in another, e.g., opposite, direction. Thus, the undulations may form a sine wave, or "S" shape.

[0045] A corrugation may include multiple folds. For example, a corrugation may refer to a step change in the direction of a heating element followed by another step change in the direction of the heating element. Thus, a corrugation may form three sides of a rectangle, or an "M" shape, or an "N" shape.

[0046] Advantageously, a heating element including one or more of curves, undulations, folds, and corrugations may simplify the manufacture of a heater assembly having at least a portion of the heating element embedded in the liquid aerosol-forming substrate storage component and at least a portion not embedded in the liquid aerosol-forming substrate storage component. Furthermore, one or more of the curves, undulations, folds, and corrugations may enable the heating element to generate areas of higher temperature. For example, a portion of the heating element embedded in the liquid aerosol-forming substrate storage component may have a rigidly curved "S" shape. An area of ​​the liquid aerosol-forming substrate storage component around this portion of the heating element may be heated to a higher temperature.

[0047] The heating element may include one or more of irregular undulations and irregular corrugations along the length of the heating element. As used herein, the terms irregular undulations and irregular corrugations refer to undulations and corrugations that do not have a constant amplitude and frequency.

[0048] The amplitude of the undulations or corrugations may be measured in a direction perpendicular to the length of the heating element. The amplitude of the undulations or corrugations may be measured in the direction of the thickness of the heating element. Amplitude may refer to half the difference in height between the peak or maximum of the undulations or corrugations and the trough or minimum of the undulations or corrugations.

[0049] The frequency of an undulation or wave refers to the number of repeating cycles per unit distance, for example along the length of the heating element or in the direction between the first and second ends of the heating element. This type of frequency is often called spatial frequency. For example, if the heating element contains a regular sine wave, the wave is considered to be an undulation, and the frequency of those undulations is 1 divided by the wavelength of the wave.

[0050] An example of a regular undulation is a predictable sine wave, having a constant amplitude and frequency.

[0051] The frequency of the undulations or corrugations of the heating element may vary along the length of the heating element.

[0052] The amplitude of the undulations or corrugations of the heating element may vary along the length of the heating element.

[0053] Advantageously, varying the amplitude, or frequency, or both, may allow greater control of the location of the higher and lower temperature regions. Alternatively, or additionally, varying the amplitude, or frequency, or both, may allow greater control of the temperature difference between the higher and lower temperature regions.

[0054] The heater assembly may comprise a reservoir for storing the liquid aerosol-forming substrate.The heater assembly may comprise a reservoir of liquid aerosol-forming substrate.

[0055] The liquid aerosol-forming substrate storage component may store, or be configured to store, a liquid aerosol-forming substrate.

[0056] The liquid aerosol-forming substrate storage component may be in fluid communication with the reservoir. In this case, in use, sections of the heating element that are further away from the reservoir of the liquid aerosol-forming substrate, or areas in the liquid aerosol-forming substrate storage component around these sections of the heating element, may reach a higher temperature than sections or areas closer to the reservoir of the liquid aerosol-forming substrate. This is because more heat may be transferred from the heating element to the reservoir of the liquid aerosol-forming substrate for sections of the heating element that are closer to the reservoir of the liquid aerosol-forming substrate, or heat may be transferred faster.

[0057] Advantageously, the liquid aerosol-forming substrate storage component is in fluid communication with the reservoir such that the liquid aerosol-forming substrate can be vaporized and removed from the liquid aerosol-forming substrate storage component and quickly and automatically replenished.

[0058] The liquid aerosol-forming substrate storage component may include or be a material that is immersed in or configured to be immersed in the liquid aerosol-forming substrate. The liquid aerosol-forming substrate storage component may have a fibrous or spongy structure. The liquid aerosol-forming substrate storage component may include a capillary material. The liquid aerosol-forming substrate storage component may include a bundle of capillaries. For example, the liquid aerosol-forming substrate storage component may include one or more of fibers, threads, and microtubes.

[0059] The liquid aerosol-forming substrate storage component may comprise 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 channels through which liquid can be transported by capillary action.

[0060] The liquid aerosol-forming substrate storage component may comprise any suitable material or combination of materials. Suitable materials include, but are not limited to, sponge or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, foamed metal or plastic materials, fibrous materials, such as those made of spun or extruded fibers (such as cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics). The liquid aerosol-forming substrate storage component may comprise a ceramic material. The liquid aerosol-forming substrate storage component may have any suitable capillarity and porosity to be used with different liquid aerosol-forming substrates with different physical properties.

[0061] The heating element may comprise a fifth portion, the fifth portion being located in the reservoir. The term "reservoir" may be used to refer to a reservoir for storing a liquid aerosol-forming substrate or a reservoir of a liquid aerosol-forming substrate, unless otherwise specified. The term "reservoir" may be used to refer to a reservoir for storing a free-flowing liquid aerosol-forming substrate or a reservoir of a free-flowing liquid aerosol-forming substrate, unless otherwise specified.

[0062] The reservoir may be configured to or may store at least 0.2, 0.5, or 1 milliliter of the liquid aerosol-forming substrate. The reservoir may be configured to or may store less than 2, 1.8, or 1.5 milliliters of the liquid aerosol-forming substrate.

[0063] The heating element may be perforated. The heating element may be a mesh heating element. The heating element may include a mesh. The first portion, or the second portion, or both the first and second portions may include perforations or a mesh. The third portion, or the fourth portion, or both the third and fourth portions may include perforations or a mesh.

[0064] Advantageously, a mesh heating element or a heating element comprising a mesh can provide a large surface area in contact with the liquid aerosol-forming substrate, which can provide efficient evaporation of the liquid aerosol-forming substrate.

[0065] The heater assembly may include a second heating element. Features described in relation to the first heating element may apply to the second heating element. Similarly, features described in relation to a portion of the first heating element may apply to a corresponding portion or portions of the second heating element. For example, one or more of the material and shape of the first heating element may apply to the second heating element. Alternatively, the second heating element may have a different shape or form than the heating element.

[0066] Advantageously, the second heating element may increase the evaporation rate of the liquid aerosol-forming substrate in the liquid aerosol-forming substrate storage component. Furthermore, the distance between the first and second heating elements may be selected to affect the temperature of the region of the liquid aerosol-forming substrate storage component in use. For example, a region of the liquid aerosol-forming substrate storage component where the first and second heating elements are close to each other may reach a higher temperature than a region where the first and second heating elements are further apart.

[0067] The second heating element may include a first portion. The second heating element may include a second portion. The second heating element may include a third portion. The second heating element may include a fourth portion. The second heating element may include a fifth portion.

[0068] The second portion may extend between the first portion and the third portion. The third portion may extend between the second portion and the fourth portion.

[0069] A first portion of the second heating element may not be embedded in the liquid aerosol-forming substrate storage component. A second portion of the second heating element may not be embedded in the liquid aerosol-forming substrate storage component. A third portion of the second heating element may be embedded in the liquid aerosol-forming substrate storage component. A fourth portion of the second heating element may not be embedded in the liquid aerosol-forming substrate storage component. A fifth portion of the second heating element may be located in the reservoir.

[0070] This advantageously allows for the creation of more areas of relatively high temperature and more areas of relatively low temperature in the liquid aerosol-forming substrate storage component.

[0071] The secondary heating element may be woven into and out of the liquid aerosol-forming substrate storage component.

[0072] The second heating element may include one or more of curves, undulations, creases, and corrugations.

[0073] The second heating element may be spaced from the heating element transversely to the length of the heating element. The second heating element may be spaced from the heating element widthwise of the heating element. The second heating element may be located adjacent to the first heating element.

[0074] The second heating element may be a mesh heating element. The second heating element may include a mesh.

[0075] The first heating element and the second heating element may not be electrically connected.

[0076] The first heating element may be configured for inductive heating.The first heating element may be configured for inductive heating.

[0077] The first heating element and the second heating element may be independently operable. It may be possible to resistively or inductively heat the first heating element without substantially resistively or inductively heating the second heating element. It is possible to increase the temperature of the first heating element without substantially increasing the temperature of the second heating element. The first heating element and the second heating element may be connected to different power sources.

[0078] The first portion, or the second portion, or both the first and second portions of the heating element may be configured to be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. In use, the first portion, or the second portion, or both the first and second portions of the heating element may be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius.

[0079] The third portion, or the fourth portion, or both the third and fourth portions of the heating element may be configured to be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. In use, the third portion, or the fourth portion, or both the third and fourth portions of the heating element may be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius.

[0080] The fifth portion of the heating element may be configured to be heated, and may be heated, in use, to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. In use, the fifth portion of the heating element may be heated, in use, to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius.

[0081] The liquid aerosol-forming substrate storage component may be configured to store or may store at least 0.02, 0.05, 0.1, 0.2, or 0.5 milliliters of liquid aerosol-forming substrate.

[0082] According to another aspect of the present disclosure, there is provided a method of assembling a heater assembly. The heater assembly may be a heater assembly according to the present disclosure. The method may include providing a liquid aerosol-forming substrate storage component. The method may include providing a heating element including a first portion and a second portion. The method may include embedding the first portion of the heating element in the liquid aerosol-forming substrate storage component.

[0083] Where the heating element includes a third portion, the method may include embedding the third portion of the heating element in the liquid aerosol-forming substrate storage component.

[0084] According to another aspect of the present disclosure, there is provided a cartridge. The cartridge may include a heater assembly according to the present disclosure.

[0085] The cartridge may be configured to engage and disengage with the aerosol generation device. The aerosol generation device may include a power source. The power source may be configured to provide power to the heating element. The power source may be configured to provide power to the heating element only when the cartridge is engaged with the aerosol generation device.

[0086] The cartridge may include an air inlet. The cartridge may include an air outlet. The air inlet may be in fluid communication with the air outlet. The heating element may be located downstream of the air inlet. The heating element may be located upstream of the air outlet. In use, this may allow air to flow through the air inlet and then across, over, past or through the heater assembly or heating element before passing through the air outlet.

[0087] The cartridge may include a mouthpiece. The mouthpiece may include an air outlet. In use, when the cartridge is engaged with an aerosol generating device, a user may inhale into the mouthpiece of the cartridge. This may cause air to flow through the air inlet and then across, over, through or through the heater assembly or heating element before passing through the air outlet.

[0088] Advantageously, providing an air flow across, across, past or through the heater assembly or heating element may allow vapour formed by the heater assembly to be entrained in the air flow.

[0089] The cartridge may include first and second electrical contacts electrically connected to the heating element, the electrical contacts may include one or more of 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 enhance resistance to organic acids.

[0090] The electrical contacts may be configured to form an electrical connection with corresponding electrical contacts on the aerosol generation device when the cartridge is engaged with the aerosol generation device.

[0091] The second portion, or the fourth portion, or both the second portion and the fourth portion of the heating element may be located in the airflow path between the air inlet of the cartridge and the air outlet of the cartridge.

[0092] Advantageously, in use, this can increase the temperature of the airflow, which some users may prefer, which can more accurately mimic the experience of smoking a traditional cigarette or cigar.

[0093] According to another aspect of the present disclosure, there is provided an aerosol generation system, the system may comprise a heater assembly according to the present disclosure.

[0094] An aerosol generation system may comprise a cartridge according to the present disclosure.

[0095] The system may include an aerosol generating device.The system may include a cartridge including a heater assembly.

[0096] The cartridge may be configured to engage with an aerosol generation device. The cartridge may be configured to disengage from an aerosol generation device.

[0097] The aerosol generation system may include a power source, such as a battery, for example, an aerosol generator of the aerosol generation system. The power source may be configured to provide power to the heating element, which may be to heat the heating element. The power source may be configured to provide power to the heating element only when the cartridge is engaged with the aerosol generation device.

[0098] The aerosol generating device may include a controller. The controller may be configured to control the supply of power from the power source and thus the heating of the heating element.

[0099] The power supply may be configured to supply power to the heating element to resistively heat the heating element.The power supply may be configured to supply power to the heating element to inductively heat the heating element.

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

[0101] The aerosol generating device may comprise an air inlet.The aerosol generating device may comprise an air outlet.When the aerosol generating device is engaged with the cartridge, the air outlet of the aerosol generating device may be in fluid communication with the air inlet of the cartridge.

[0102] The power source 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 corresponding first and second electrical contacts on the cartridge when the cartridge is engaged with the device. These corresponding first and second electrical contacts on the cartridge may be electrically connected to the heating element. Thus, the power source may be configured to provide power to the heating element by passing an electrical current through the heating element.

[0103] The cartridge, or aerosol generator, may include an inductor, such as an induction coil. The heating element may be or include a susceptor material.

[0104] The power supply may be configured to pass a current, such as a high frequency alternating current, through the inductor such that the inductor generates a varying electromagnetic field. This may then generate eddy currents and hysteresis losses in the susceptor material. This may heat the susceptor material. Thus, the power supply using the inductor may be configured to inductively heat the heating element.

[0105] Suitable susceptor materials include those previously described with reference to heater assemblies according to the present disclosure.

[0106] The inductor may be an induction coil. The inductor may be located within a cartridge that includes the heater assembly. The inductor may be disposed around the heating element or around a portion of the heating element. For example, the inductor may be an induction coil and may be spiraled around the heating element or around a portion of the heating element.

[0107] The inductor may be electrically connected to electrical contacts on the cartridge. When the cartridge is engaged with the aerosol generating device, these electrical contacts may be electrically connected to corresponding electrical contacts on the device that are electrically connected to a power source of the device. When the cartridge is engaged with the device, the power source of the device may be configured to pass a current through the inductor to generate a varying electromagnetic field, thereby heating the susceptor material of the heating element.

[0108] An inductor, such as an induction coil, may be located within the aerosol generating device. The inductor may be electrically connected to a power supply of the aerosol generating device. The aerosol generating device may be configured to engage with a heater assembly or a cartridge including the heater assembly. For example, the device may include a chamber for receiving at least a portion of the heater assembly, or at least a portion of the cartridge including the heater assembly. The induction coil may be disposed around at least a portion of the chamber. For example, the induction coil may be spiraled around at least a portion of the chamber. Thus, when the heater assembly, or at least a portion of the cartridge including the heater assembly, engages with the device, the induction coil may be disposed around or may be spiraled around the heating element, or a portion of the heating element. When at least a portion of the heater assembly, or at least a portion of the cartridge including the heater assembly, is received within the chamber of the device, the power supply of the device may be configured to pass a current through the inductor to generate a varying electromagnetic field, thereby heating the susceptor material of the heating element.

[0109] As discussed above, induction heating may advantageously allow for simple, inexpensive, and robust manufacture of cartridges. Additionally, induction heating may provide improved energy conversion compared to resistive heating.

[0110] The aerosol generation system may be a smoke system, for example an electrically operated smoking system. The aerosol generation system may be for recreational use. In use, the aerosol generation system may be suitable or configured to deliver nicotine to a user.

[0111] The aerosol generating system may be portable. The aerosol generating system may have a size comparable to a conventional cigar or cigarette. The smoking system may have an overall length of 30 millimeters to 200 millimeters. The smoking system may have an outer diameter of 5 millimeters to 30 millimeters. As used herein, the term "aerosol" refers to a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets in a gas. The aerosol may be visible or invisible. The aerosol may also include vapors of a substance that is normally a liquid or solid at room temperature, as well as solid particles or droplets, or a combination of solid particles and droplets.

[0112] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating or burning the aerosol-forming substrate.

[0113] The aerosol-forming substrate may comprise a plurality of compounds. The compounds may have different boiling points. For example, the aerosol-forming substrate may comprise a first compound having a first boiling point at atmospheric pressure and a second compound having a second boiling point at atmospheric pressure, the first boiling point being higher than the second boiling point.

[0114] The aerosol-forming substrate may include an aerosol former. As used herein, the term "aerosol former" refers to any suitable compound or mixture of compounds that, when used, facilitates the formation of an aerosol, for example, a stable aerosol that is substantially resistant to thermal degradation at the operating temperature of the system. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate, etc.), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.).

[0115] The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise water. The aerosol-forming substrate may comprise glycerol, also called glycerin, which has a higher boiling point than nicotine. The aerosol-forming substrate may comprise propylene glycol. The aerosol-forming substrate may comprise plant-derived material. The aerosol-forming substrate may comprise homogenized plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise tobacco-containing material. The tobacco-containing material may contain volatile tobacco flavour compounds. These compounds may be released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may comprise homogenized tobacco material. The aerosol-forming substrate may comprise other additives and ingredients such as flavourants.

[0116] As used herein, the term "liquid aerosol-forming substrate" is used to refer to an aerosol-forming substrate in a condensed form. Thus, a "liquid aerosol-forming substrate" may be or include one or more of a liquid, a gel, or a paste. If the liquid aerosol-forming substrate is or includes a gel or paste, the gel or paste may liquefy upon heating. For example, the gel or paste may liquefy when heated to a temperature below 50, 75, 100, 150, or 200 degrees Celsius.

[0117] As used herein, the term "heating element" refers to a heater element, an element configured to heat. For example, the term "heating element" can refer to an element configured to be heated to at least 50, 100, 150, 200, 250, 300, 350, or 400 degrees Celsius. The heating element, or a portion thereof, may be configured to be resistively heated. Alternatively, or additionally, the heating element, or a portion thereof, may be configured to be inductively heated.

[0118] As used herein, the term "embedded" may be used to mean surrounded, enveloped, enclosed, surrounded, or surrounded. Additionally, when a first component is "embedded" in a second component, this may mean that the first component is in contact with the second component. For example, when a portion of a heating element is described as being embedded in a component, this may mean that this portion of the heating element is surrounded by and in contact with the component. EXAMPLES

[0119] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0120] Example 1: 1. A heater assembly for use in an aerosol generating system, comprising: a liquid aerosol-forming substrate storage component; a heating element including a first portion and a second portion; A heater assembly, wherein a first portion of the heating element is embedded in the liquid aerosol-forming substrate storage component, and a second portion of the heating element is not embedded in the liquid aerosol-forming substrate storage component. Example 2: The heater assembly of example 1, wherein the heating element comprises a third portion and a fourth portion, the third portion of the heating element being embedded in the liquid aerosol-forming substrate storage component, and the fourth portion of the heating element being not embedded in the liquid aerosol-forming substrate storage component. Example 3: The heater assembly of example 2, wherein the second portion of the heating element extends between the first portion and the third portion. Example 4: The heater assembly of example 2 or example 3, wherein the third portion of the heating element extends between the second portion and the fourth portion. Example 5: 5. The heater assembly of any of Examples 2-4, wherein the third section and the fourth section are configured to be resistively heated. Example 6: 6. The heater assembly of any of Examples 2-5, wherein the third portion and the fourth portion comprise an electrically resistive material. Example 7: 7. The heater assembly of any of Examples 1-6, wherein the first portion and the second portion are configured to be resistively heated. Example 8: 8. The heater assembly of any of Examples 1-7, wherein the first portion and the second portion comprise an electrically resistive material. Example 9: 5. The heater assembly of any of claims 2-4, wherein the third section and the fourth section are configured to be inductively heated. Example 10: The heater assembly of any of Examples 2-4 or 9, wherein the third portion and the fourth portion comprise a susceptor material. Example 11: The heater assembly of any of Examples 1-4, 9, or 10, wherein the first portion and the second portion are configured to be inductively heated. Example 12: The heater assembly of any of Examples 1-4, 9, 10, or 11, wherein the first portion and the second portion comprise a susceptor material. Example 13: 13. The heater assembly of any one of Examples 1-12, wherein the heating element comprises a strip of material. Example 14: 14. The heater assembly of any of Examples 1-13, wherein the cross-section of the heating element varies along the length of the heating element. Example 15: The heater assembly of any of Examples 1-14, wherein the minimum cross-sectional area along the length of the heating element is at least 10 percent less than the maximum cross-sectional area along the length of the heating element. Example 16: 16. The heater assembly of any of Examples 1-15, wherein the width or thickness, or both the width and thickness, of the heating element varies along the length of the heating element. Example 17: The heater assembly of any of Examples 1-16, wherein the heating element is woven into and out of the liquid aerosol-forming substrate storage component. Example 18: The heater assembly of any one of Examples 1-17, wherein the heating element comprises one or more of a curve, an undulation, a fold, and a wave shape. Example 19: The heater assembly of any of Examples 1-18, wherein the heating element comprises one or more of irregular undulations and irregular corrugations along the length of the heating element. Example 20: 20. The heater assembly of any of Examples 1-19, wherein the frequency of the undulations or corrugations of the heating element varies along the length of the heating element. Example 21: 21. The heater assembly of any of Examples 1-20, wherein the amplitude of the undulations or corrugations of the heating element varies along the length of the heating element. Example 22: 22. A heater assembly as described in any of Examples 1-21, comprising a reservoir for storing a liquid aerosol-forming substrate. Example 23: 23. The heater assembly of example 22, wherein the reservoir is in fluid communication with a liquid aerosol-forming substrate storage component. Example 24: 24. The heater assembly of example 22 or 23, wherein the heating element comprises a fifth portion, the fifth portion located within the reservoir. Example 25: 25. The heater assembly of example 22, 23, or 24, wherein the reservoir contains at least 1 milliliter of the liquid aerosol-forming substrate. Example 26: The heater assembly of any one of Examples 1-25, comprising a second heating element. Example 27: The heater assembly of example 26, wherein a second heating element is woven into and out of the liquid aerosol-forming substrate storage component. Example 28: 28. The heater assembly of example 26 or 27, wherein the second heating element comprises one or more of a curve, an undulation, a fold, and a wave shape. Example 29: 29. The heater assembly of any of Examples 26-28, wherein the second heating element is spaced from the heating element laterally relative to the length of the heating element. Example 30: 30. The heater assembly of any of Examples 26-29, wherein the second heating element is a mesh heating element. Example 31: 31. The heater assembly of any of Examples 1-30, wherein, in use, both the first portion and the second portion are heated to at least 50 degrees Celsius. Example 32: The heater assembly of any one of Examples 1-31, wherein the heating element is a mesh heating element. Example 33: The heater assembly of any of Examples 1-32, wherein the liquid aerosol-forming substrate storage component comprises a capillary retention material. Example 34: The heater assembly of any of Examples 1-33, wherein the liquid aerosol-forming substrate storage component is configured to store at least 0.05 milliliters of the liquid aerosol-forming substrate. Example 35: The heater assembly of any of Examples 1-34, wherein at least 0.05 milliliters of the liquid aerosol-forming substrate is stored in the liquid aerosol-forming substrate storage component. Example 36: A cartridge comprising a heater assembly according to any one of Examples 1 to 35. Example 37: A method of assembling the heater assembly of any one of Examples 1 to 35, comprising: Providing a liquid aerosol-forming substrate storage component; providing a heating element including a first portion and a second portion; embedding a first portion of the heating element in a liquid aerosol-forming substrate storage component. Example 38: An aerosol generating system comprising a heater assembly described in any one of Examples 1 to 35. Example 39: The aerosol generation system of Example 38, wherein the system comprises a cartridge comprising an aerosol generating device and a heater assembly. Example 40: 40. The aerosol generation system of example 39, wherein the cartridge is configured to engage and disengage with the aerosol generation device. Example 41: An aerosol generation system described in any of Examples 38, 39, or 40, wherein the aerosol generation system comprises a power source configured to supply power to the heating element to heat the heating element. Example 42: An aerosol generation system as described in Example 39 or 40, wherein the aerosol generating device comprises a power source configured to supply power to the heating element to heat the heating element. Example 43: An aerosol generation system as described in Example 41 or 42, wherein the power supply is configured to supply power to the heating element to resistively heat the heating element. Example 44: An aerosol generation system as described in Example 41 or 42, wherein the power supply is configured to supply power to the heating element to inductively heat the heating element. Example 45: 45. The aerosol generating system according to any one of Examples 38 to 44, wherein the aerosol generating system has a total length of 30 millimeters to 200 millimeters. Example 46: 46. ​​The aerosol generating system according to any one of Examples 38 to 45, wherein the aerosol generating system has an outer diameter of 5 millimeters to 30 millimeters. Example 47: The aerosol generating system according to any one of Examples 38 to 46, wherein the aerosol generating system is portable. Example 48: 48. The aerosol generating system according to any one of Examples 38 to 47, wherein the aerosol generating system is a smoke extraction system. [Brief description of the drawings]

[0121] The embodiments will now be further described with reference to the figures.

[0122] [Figure 1] FIG. 1 shows a schematic cross-sectional view of a first aerosol generation system including a cartridge incorporating a first heater assembly. [Diagram 2] FIG. 2 shows a schematic cross-sectional view of the first heater assembly. [Diagram 3] FIG. 3 shows a schematic perspective view of the first heater assembly. [Figure 4] FIG. 4 is a schematic cross-sectional view of a second aerosol generating system including a cartridge incorporating a second heater assembly. [Diagram 5] FIG. 5 shows a schematic cross-sectional view of a second heater assembly. [Figure 6] FIG. 6 shows a schematic perspective view of a second heater assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0123] 1 shows a schematic cross-sectional view of a first aerosol generation system 100. The aerosol generation system 100 comprises an aerosol generating device 150 and a cartridge 200. In this embodiment, the aerosol generation system 100 is an electrically operated smoking system.

[0124] The aerosol generating device 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, 158 electrically connected to the battery 152. This electrical connection is a wired connection and is not shown in FIG.

[0125] The cartridge 200 comprises first and second electrical contacts 214, 216, an air inlet 202, an air outlet 204, and a first heater assembly 300. The air inlet 202 is in fluid communication with the air outlet 204. The heater assembly 300 is positioned downstream of the air inlet 202 and upstream of the air outlet 204. The heater assembly 300 includes a liquid aerosol-forming substrate storage component 302 in fluid communication with a reservoir 303 of liquid aerosol-forming substrate. The heater assembly 300 also includes a heating element 304. The first and second electrical contacts 214, 216 are electrically connected to the heating element 304.

[0126] In this system 100, the liquid aerosol-forming substrate comprises approximately 74% by weight glycerin, 24% by weight propylene glycol, and 2% by weight nicotine, although any suitable substrate may be used. At atmospheric pressure, nicotine has a boiling point of approximately 247 degrees Celsius, glycerin has a boiling point of approximately 290 degrees Celsius, and propylene glycol has a boiling point of approximately 188 degrees Celsius. Thus, when this liquid aerosol-forming substrate is first heated to form an aerosol, some systems may undesirably vaporize a disproportionate amount of propylene glycol (which has the lowest boiling point of the compounds forming the substrate). This may lead to a less desirable aerosol being delivered to the user, such as an aerosol containing a lower percentage of nicotine than desired. This may also result in undesirable changes in the relative ratios of the compounds in the substrate over a longer period of time. The present invention may eliminate or at least reduce these undesirable effects.

[0127] The heating element 304 is a strip of material. In this example, the material is stainless steel, but any suitable material may be used. The heating element 304 comprises a first portion 306, a second portion 308, a third portion 310, and a fourth portion 312. The second portion 308 extends between the first portion 306 and the third portion 310. The third portion 310 extends between the second portion 308 and the fourth portion 312. The first portion 306 and the third portion 310 are embedded in the liquid aerosol-forming substrate storage component 302. The second portion 308 and the fourth portion 312 are not embedded in the liquid aerosol-forming substrate storage component 302. In the example shown in FIG. 1, the second portion 308 and the fourth portion 312 are located in the airflow path between the air inlet 202 and the air outlet 204 of the cartridge 200.

[0128] 1, the aerosol generation device 150 is engaged with a cartridge 200. In this embodiment, the cartridge 200 engages with the aerosol generation device 150 via threads 206 of the cartridge 200 that mate with corresponding threads 162 of the aerosol generation device 150.

[0129] The liquid aerosol-forming substrate storage component 302 in this example is a capillary material having a fibrous structure. In the example shown in Figure 1, the capillary material is made from polyester, although any suitable material may be used.

[0130] In use, a user draws on the air outlet 204 of the cartridge 200. At the same time, the user presses a button (not shown) on the aerosol generating device 150. Pressing the button sends a signal to the controller 154, which in turn provides power to the heating element 304 from the battery 152 via the device's electrical contacts 156, 158 and the cartridge's electrical contacts 214, 216. This causes a current to flow through the heating element 304, thereby resistively heating it. In other embodiments, an airflow sensor or pressure sensor is located within the cartridge 200 and electrically connected to the controller 154. The airflow sensor or pressure sensor detects that the user is drawing on the air outlet 204 of the cartridge 200 and sends a signal to the controller 154 to provide power to the heating element 304. Thus, in these embodiments, the user does not need to press a button to heat the heating element 304.

[0131] When the heating element 304 is heated, regions of relatively high and relatively low temperature are created in the liquid aerosol-forming substrate storage component 302. Regions of relatively low temperature may be created in regions where the heating element 304 is closer to the reservoir 303 of the liquid aerosol-forming substrate. This is because heat from the heating element 304 in these regions dissipates more quickly into the reservoir 303. Regions of relatively low temperature may be created in regions further away from the heating element. Regions of relatively high temperature may be created due to the shape of the heating element. For example, the heating element may be shaped such that a larger volume or a larger surface area of ​​the heating element is present in a given volume at a first location in the liquid aerosol-forming substrate storage component than is present in the same given volume at a second location of the liquid aerosol-forming substrate storage component. In this case, the average temperature of the liquid aerosol-forming substrate at the first location may be higher than the average temperature of the liquid aerosol-forming substrate at the second location.

[0132] The creation of higher and lower temperature regions simultaneously vaporizes the higher and lower boiling point compounds of the liquid aerosol-forming substrate of the liquid aerosol-forming substrate storage component 302. The creation of higher and lower temperature regions also causes the higher and lower boiling point compounds of the liquid aerosol-forming substrate of the liquid aerosol-forming substrate storage component 302 to vaporize at a desired rate.

[0133] As the user puffs on the air outlet 204 of the cartridge 200, air is drawn into the air inlet 202. This air then travels across the heater assembly 300 towards the air outlet 204. This air flow entrains vapor formed by the heating element 304 which heats the liquid aerosol-forming substrate in the liquid aerosol-forming substrate storage component 302. As described above, areas of higher and lower temperature are created so that the vapor contains different compounds with different boiling points in desired proportions. This entrained vapor is then cooled and condenses to form an aerosol. This aerosol is then delivered to the user via the air outlet 204. As the liquid aerosol-forming substrate in the liquid aerosol-forming substrate storage component 302 is heated, vaporized and entrained in the airflow, the liquid aerosol-forming substrate from the reservoir 303 travels into the liquid aerosol-forming substrate storage component 302. This liquid aerosol-forming substrate from the reservoir 303 effectively replaces the vaporized liquid aerosol-forming substrate. The liquid aerosol-forming substrate from the reservoir 303 may be drawn into the liquid aerosol-forming substrate storage component 302 at least in part by capillary action, because the liquid aerosol-forming substrate storage component 302 is a capillary material having a fibrous structure.

[0134] FIG. 2 shows a schematic cross-sectional view of the first heater assembly 300. In FIG. 2, the width of the heating element 304 is in the direction into the drawing and may vary, but is constant in the example shown in FIG. 2. However, as shown in FIG. 2, the thickness of the heating element 304 is not constant. Rather, the thickness gradually decreases from the second portion 308 to the third portion 310, and then gradually increases from the third portion 310 to the fourth portion 312. The minimum thickness of the heating element 304 is at the third portion 310, which is embedded in the liquid aerosol-forming substrate storage component 302. This minimum thickness of the heating element 304 is about 50 percent of the maximum thickness of the heating element at the first portion 306. Thus, the resistance of the third portion 310 is greater than the resistance of the other portions, and in use, the third portion 310 is resistively heated to a higher temperature than the other portions. This may advantageously increase the temperature of the liquid aerosol-forming substrate close to the third portion 310 of the heating element 304.

[0135] Figure 3 shows a schematic perspective view of a first heater assembly 300. As shown in Figure 3, the heating element 304 includes curved lines and is woven in and out of the liquid aerosol-forming substrate storage component 302. The ends of the heating element 304 extend from the liquid aerosol-forming substrate storage component 302 to allow for easy electrical connection to electrical contacts (not shown in Figure 3) of the cartridge 200.

[0136] 4 shows a schematic cross-sectional view of a second aerosol generation system 400. The aerosol generation system 400 comprises an aerosol generating device 450 and a cartridge 500 incorporating a second heater assembly 600. In this embodiment, the aerosol generation system 400 is an electrically operated smoking system.

[0137] The aerosol generating device 450 is portable and has a size comparable to a conventional cigar or cigarette. The device 450 includes a battery 452, such as a lithium iron phosphate battery, and a controller 454 electrically connected to the battery 452. The device 450 also includes an induction coil 456 electrically connected to the battery 452. The device 450 also includes an air inlet 458 and an air outlet 460 in fluid communication with the air inlet 458.

[0138] The cartridge 500 comprises an air inlet 502, an air outlet 504, and a second heater assembly 600. The air inlet 502 is in fluid communication with the air outlet 504. The heater assembly 600 is positioned downstream of the air inlet 502 and upstream of the air outlet 504. As shown in Figure 4, when the cartridge 500 is engaged with an aerosol generating device 450, the air outlet 460 of the device 450 is adjacent to the air inlet 502 of the cartridge 500. Thus, during use, when a user puffs on the air outlet 504 of the cartridge 500, air flows through the air inlet 458 of the device 450, then through the air outlet 460 of the device 450, then through the air inlet 502 of the cartridge 500, then through the heater assembly 600, and then through the air outlet 504 of the cartridge 500.

[0139] 4, cartridge 500 is engaged with aerosol generation device 450. In this embodiment, cartridge 500 is engaged with aerosol generation device 450 via openings 506, 508 that form a snap-fit ​​connection with corresponding protrusions 462, 464 on aerosol generation device 450.

[0140] Heater assembly 600 comprises a first heating element 604, a second heating element (not visible in FIG. 4), a reservoir 603 of liquid aerosol-forming substrate, and a liquid aerosol-forming substrate storage component 602 in fluid communication with reservoir 603. The second heating element 605 is not visible in FIG. 4 but is visible in FIG.

[0141] In this system 400, the liquid aerosol-forming substrate comprises about 98% glycerin and 2% nicotine by weight, although any suitable substrate may be used. At atmospheric pressure, nicotine has a boiling point of about 247 degrees Celsius, and glycerin has a boiling point of about 290 degrees Celsius. Thus, when this liquid aerosol-forming substrate is first heated to form the aerosol, some systems may undesirably vaporize a disproportionate amount of nicotine (which has the lowest boiling point of the compounds forming the substrate). This may lead to a less desirable aerosol being delivered to the user. This may also lead to undesirable changes in the relative ratios of the compounds in the substrate over a longer period of time. The present invention may eliminate or at least reduce these undesirable effects.

[0142] The first heating element 604 includes a strip of susceptor material. In this example, the susceptor material is aluminum, but any suitable susceptor material may be used. The first heating element 604 includes portions embedded in the liquid aerosol-forming substrate storage component 602 and portions not embedded in the liquid aerosol-forming substrate storage component 602. Two of the portions not embedded in the liquid aerosol-forming substrate storage component 602 are located within the reservoir 603.

[0143] 4, the second heating element 605 is identical to the first heating element 604, although two (or more) different heating elements may be used. The second heating element 605 is located adjacent to the first heating element 604.

[0144] The liquid aerosol-forming substrate storage component 602 in this example is a capillary material having a fibrous structure. The capillary material is formed from polyester, although any suitable material may be used.

[0145] In use, a user draws on the air outlet 504 of the cartridge 500. At the same time, the user presses a button (not shown) on the aerosol generating device 450. Pressing the button sends a signal to the controller 454, which causes the battery 452 to supply a high frequency current to the induction coil 456. This causes the induction coil 456 to generate a varying electromagnetic field. The first heating element 604 and the second heating element 605 are positioned within this field. This varying electromagnetic field therefore generates eddy currents and hysteresis losses in the first heating element 604 and the second heating element 605. Thus, the first heating element 604 and the second heating element 605 are inductively heated. In another embodiment, an airflow sensor or a pressure sensor is located within the device 450 and electrically connected to the controller 454. The airflow or pressure sensor detects when a user draws on the air outlet 504 of the cartridge 500 and sends a signal to the controller 454 to provide high frequency current to the induction coil 456, thereby heating the first heating element 604 and the second heating element 605. Thus, in these embodiments, the user does not need to press a button to heat the first heating element 604 and the second heating element 605.

[0146] When the first heating element 604 and the second heating element 605 are heated, regions of relatively high and relatively low temperatures are generated in the liquid aerosol-forming substrate storage component 602. Regions of lower temperature may be generated in regions where the heating element 604 is closer to the reservoir 603 of the liquid aerosol-forming substrate. This is because heat from the heating element 604 in these regions dissipates more quickly into the reservoir 603. Regions of relatively low temperature may be generated in regions further away from the heating element. Regions of relatively high temperature may be generated due to the shape of the heating element. For example, the heating element may be shaped such that a larger volume or a larger surface area of ​​the heating element is present in a given volume at a first location in the liquid aerosol-forming substrate storage component than is present in the same given volume at a second location of the liquid aerosol-forming substrate storage component. In this case, the average temperature of the liquid aerosol-forming substrate at the first location may be higher than the average temperature of the liquid aerosol-forming substrate at the second location.

[0147] The creation of higher and lower temperature regions causes the higher and lower boiling point compounds of the liquid aerosol-forming substrate of the liquid aerosol-forming substrate storage component 602 to vaporize simultaneously. The creation of higher and lower temperature regions also causes the higher and lower boiling point compounds of the liquid aerosol-forming substrate of the liquid aerosol-forming substrate storage component 302 to vaporize at a desired rate.

[0148] As the user puffs on the air outlet 504 of the cartridge 500, air is drawn into the air inlet 458 of the device 450, then through the air outlet 460 of the device 450, and then through the air inlet 502 of the cartridge 500. The air then moves around the heater assembly 600 toward the air outlet 504. This air flow entrains vapor formed by heating the liquid aerosol-forming substrate by the first heating element 604 and the second heating element 605. As described above, because areas of higher and lower temperature are created, the vapor contains the desired proportions of different compounds with different boiling points. The entrained vapor is then cooled and condensed to form an aerosol. The aerosol is then delivered to the user via the air outlet 504.

[0149] FIG. 5 shows a schematic cross-sectional view of a second heater assembly 600.

[0150] The first heating element 604 comprises a first portion 606, a second portion 608, a third portion 610, a fourth portion 612, a fifth portion 614, a sixth portion 616, a seventh portion 618, an eighth portion 620, and a ninth portion 622. The first portion 606, the third portion 610, the fifth portion 614, the seventh portion 618, and the ninth portion 622 are embedded in the liquid aerosol-forming substrate storage component 602. The second portion 608, the fourth portion 612, the sixth portion 616, and the eighth portion 620 are not embedded in the liquid aerosol-forming substrate storage component 602. The second portion 608 and the eighth portion 620 are located in the airflow path between the air inlet 502 and the air outlet 504 of the cartridge 500. The fourth portion 612 and the sixth portion 616 are located in the reservoir 603 of the liquid aerosol-forming substrate.

[0151] In FIG. 5, the various thicknesses of the first heating element 604 can be seen. The central section of the fifth portion 614 has a reduced thickness compared to the remaining portions of the first heating element 604. Specifically, the central section of the fifth portion 616 has a thickness of about 30 percent of the thickness of the remaining portions of the first heating element 604. As shown in FIG. 5, the fifth portion 614 also includes corrugations. The region of the liquid aerosol-forming substrate storage component 602 around the fifth portion 614 may be elevated to a relatively higher temperature than other regions of the liquid aerosol-forming substrate storage component 602. This is because, as the fifth portion 614 of the heating element 604 becomes thinner, the fifth portion 614 may be inductively heated to a higher temperature than other portions of the heating element 604. Alternatively, or additionally, the corrugations in the fifth portion 614 mean that the region of the liquid aerosol-forming substrate storage component 602 around the fifth portion 614 contains a larger volume and surface area of ​​the heating element 604 than other regions of a similar size of the liquid aerosol-forming substrate storage component 602. Thus, more heat can be transferred from the heating element 604 into the region of the liquid aerosol-forming substrate storage component 602 around the fifth portion 614 than other regions.

[0152] Figure 6 shows a schematic perspective view of the second heater assembly 600. In Figure 6, the second heating element 605 is visible. The second heating element 605 is identical to the first heating element 604 and is located adjacent to the first heating element 604. Thus, the second heating element 605 similarly has a portion embedded in the liquid aerosol-forming substrate storage component 602, a portion located within the reservoir 603, and a portion located within the airflow path between the air inlet 502 and the air outlet 504 of the cartridge 500. In Figure 6, the second portion 608 and the eighth portion 620 of the first heating element 604 are also visible.

[0153] The heater assemblies described herein can provide areas of higher and lower temperatures in the liquid aerosol-forming substrate storage component. Alternatively, or in addition, the heater assemblies can provide areas of higher and slower temperature increases in the liquid aerosol-forming substrate storage component. Advantageously, as described above, this can simultaneously vaporize liquid aerosol-forming substrate compounds having higher and lower boiling points at a desired rate.

[0154] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like, should be understood in all instances as modified by the term "about." Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A±10 percent. Within this context, the number A may be considered to include a numerical value that is within the general standard error for the measurement of the property that the number A modifies. The number A may deviate by the percentages recited above, in some cases as used in the appended claims, provided that the amount by which A deviates does not materially affect the basic and novel properties of the claimed invention. Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. A heater assembly for use in an aerosol generating system, comprising: a liquid aerosol-forming substrate storage component; a reservoir of free-flowing liquid aerosol-forming substrate, the reservoir being in fluid communication with the liquid aerosol-forming substrate storage component; a heating element including a first portion, a second portion, and a further portion; A heater assembly, wherein the first portion of the heating element is embedded in the liquid aerosol-forming substrate storage component, the second portion of the heating element is not embedded in the liquid aerosol-forming substrate storage component, and the further portion of the heating element is located in the storage portion.

2. 2. The heater assembly of claim 1, wherein the heating element comprises a third portion and a fourth portion, the third portion of the heating element being embedded in the liquid aerosol-forming substrate storage component and the fourth portion being not embedded in the liquid aerosol-forming substrate storage component.

3. 3. The heater assembly of claim 2, wherein the second portion of the heating element extends between the first portion and the third portion, and the third portion of the heating element extends between the second portion and the fourth portion.

4. 4. A heater assembly as described in any of claims 1 to 3, wherein the heating element comprises a strip of material having a length, a width perpendicular to the length, and a thickness perpendicular to the length and width, the length being greater than the width and greater than the thickness.

5. The heater assembly of any preceding claim, wherein the cross-section of the heating element varies along the length of the heating element.

6. 6. The heater assembly of any of claims 1 to 5, wherein the heating element extends between a first end and a second end and has a first cross-sectional area at a first point between the first end and the second end, a second cross-sectional area at a second point between the first point and the second end, and a third cross-sectional area at a third point between the second point and the second end, each of the first cross-sectional area and the third cross-sectional area being greater than or less than the second cross-sectional area.

7. The heater assembly of any of claims 1 to 6, wherein the heating element is woven into and out of the liquid aerosol-forming substrate storage component.

8. The heater assembly of any preceding claim, wherein the heating element comprises one or more of curves, undulations, creases, and corrugations.

9. The heater assembly of any preceding claim, further comprising a second heating element.

10. 10. The heater assembly of claim 9, wherein the second heating element comprises a first portion and a second portion, the first portion of the second heating element being embedded in the liquid aerosol-forming substrate storage component, and the second portion of the second heating element being not embedded in the liquid aerosol-forming substrate storage component.

11. A heater assembly according to any preceding claim, wherein, in use, both the first portion and the second portion are heated to at least 50 degrees Celsius.

12. An aerosol generating system comprising a heater assembly according to any one of claims 1 to 11.

13. 13. The aerosol generation system of claim 12, wherein the system comprises an aerosol generation device and a cartridge containing the heater assembly, the cartridge configured to engage and disengage with the aerosol generation device.

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