Aerosol-generating consumable having a fuse element - Patents.com

Abstract

The aerosol-generating consumable (120) includes a liquid reservoir (122) configured to hold an aerosol-generating liquid and define a liquid outlet opening (124) and a heating assembly (130) secured to the liquid outlet opening. The heating assembly includes a capillary body (132) defining a porous outer surface (133). The capillary body is configured to direct the aerosol-generating liquid from the liquid outlet opening to the porous outer surface. An electrically resistive heating element (140) is secured to the porous outer surface, and a thermally conductive polymer element (150) is secured to the porous outer surface. The electrically resistive heating element includes an electrical fuse portion (145) configured to terminate electrical current flow through the resistive heating element.

Description

[Technical field]

[0001] The present disclosure relates to an aerosol generating consumable having a fuse element that provides overheat protection when used in an aerosol generating system.

[0002] The sensory medium in commercially available e-cigarettes is generally a liquid (so-called "e-liquid"). These e-liquids are typically contained within aerosol-generating consumables or "pods" that are replaceable into the e-cigarette. These pods contain a heater in contact with a porous material or wick. The porous material or wick transports the e-liquid by capillary action to the heater for vaporization into the inhalation airstream of the e-cigarette. The heater in current commercially available e-cigarette systems is typically integrated into the replaceable cartridge or "pod" that contains the e-liquid.

[0003] When a used pod is consumed or depleted, the user inserts a new pod or refills the pod with aerosol-generating e-liquid. However, users may misuse the aerosol-generating system by using empty pods. This may result in a "dry hit" and may produce a burning odor or unpleasant flavor. Users may also refill empty pods with unknown or counterfeit e-liquid, contaminating the pod with incompatible e-liquid that vaporizes at a higher temperature than compatible e-liquids.

[0004] Current overheat protection requires complex configurations that increase the overall cost of the aerosol-generating consumable or pod and make the aerosol-generating consumable expensive to produce. Summary of the Invention [Problem to be solved by the invention]

[0005] There is a need for an aerosol-generating consumable that provides reliable overheat protection with a simple heating element design.

[0006] It would be desirable to provide an aerosol-generating consumable that provides reliable overheat protection with a simple heating element design.It would be desirable to provide an aerosol-generating consumable that provides improved heating efficiency.It would be desirable to provide an aerosol-generating consumable that has irreversible rupture of the heating element in response to depletion of the aerosol-generating liquid. [Means for solving the problem]

[0007] The present disclosure is directed to an aerosol generating consumable having a fuse element that provides overheat protection when used in an aerosol generating system. The aerosol generating consumable includes a heating element having an electrically resistive heating element and a thermally conductive polymer element. The electrically resistive heating element and the thermally conductive polymer element cooperate to form an overheat protection circuit that blows the fuse element when the heating element reaches a predetermined high temperature limit.

[0008] According to one aspect of the invention, there is provided an aerosol-generating consumable including a liquid reservoir configured to hold an aerosol-generating liquid and defining a liquid outlet opening, and a heating assembly secured to the liquid outlet opening. The heating assembly includes a capillary body defining a porous outer surface. The capillary body is configured to cause the aerosol-generating liquid to flow from the liquid outlet opening to the porous outer surface. An electrically resistive heating element secured to the porous outer surface, and a thermally conductive polymeric element secured to the porous outer surface. The electrically resistive heating element includes an electrical fuse portion configured to terminate electrical current flow through the resistive heating element.

[0009] According to another aspect of the invention, an aerosol generating system includes an aerosol generating device having a consumable receiving surface with device electrical contacts, a power source, and control electronics electrically connected to the power source and the device electrical contacts. The aerosol generating consumable described herein is configured to mate with the consumable receiving surface and electrically connect the device electrical contacts to an electrically resistive heating element and a thermally conductive polymer element.

[0010] A method of disabling an aerosol-generating consumable heating element includes providing an aerosol-generating system as described herein, heating an aerosol-generating liquid with the heating element to form an aerosol, sensing current across a thermally conductive polymer element on the heating element with control electronics, and delivering a blowing current to an electrically resistive electrical fuse portion of the heating element in response to the sensed low threshold current value across the thermally conductive polymer element.

[0011] It is advantageous to disable an aerosol-generating consumable with the simple and reliable overtemperature protection circuit described herein for several reasons: The temperature sensing element is a simple and reliable thermally conductive polymer element coupled to the element it senses. The fuse element is a simple and reliable circuit breaking element that disables the aerosol-generating consumable from further use. The overtemperature protection circuit irreversibly blows the heating element upon depletion of the aerosol-generating liquid, preventing operation of the aerosol-generating consumable. Once disabled, the user cannot refill the aerosol-generating liquid, preventing the use of counterfeit aerosol-generating liquid. Placing the heating element and thermally conductive polymer element on two or more surfaces of the capillary body improves the uniformity and efficiency of heating of the capillary body.

[0012] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are intended to facilitate understanding of certain terms used frequently herein.

[0013] As used herein, the singular forms "a," "an," and "the" include embodiments having plural referents unless the content clearly dictates otherwise.

[0014] As used herein, "or" is generally employed in its meaning including "and / or," unless the context clearly dictates otherwise. The term "and / or" refers to one or all of the listed elements or a combination of any two or more of the listed elements.

[0015] As used herein, the words "have," "having," "include," "including," "comprise," "comprising," and the like are used in their open-ended sense and generally mean "including, but not limited to." It should be understood that "consisting essentially of," "consisting of," and the like are encompassed by "comprising" and the like.

[0016] The words "preferred" and "preferably" refer to embodiments of the invention that may, under certain circumstances, offer certain advantages. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the present disclosure, including the claims.

[0017] The term "substantially" as used herein has the same meaning as "significantly" and can be understood to modify the associated term by at least about 90%, at least about 95%, or at least about 98%. The term "not substantially" as used herein has the same meaning as "not significantly" and can be understood to have the opposite meaning to "substantially", i.e., modifying the associated term by no more than 10%, no more than 5%, or no more than 2%.

[0018] The term "conductive material" means that-2 It refers to a material that has a resistivity of less than Ωm.

[0019] The term "capillary body" refers to a component of a heating assembly that is capable of transporting liquid aerosol-generating liquid to a heating element by capillary action.

[0020] The term "porous" means formed from a material that is permeable to the aerosol-generating liquid and allows the aerosol-generating liquid to move therethrough.

[0021] The term "nicotine" refers to nicotine and nicotine derivatives, such as free base nicotine, nicotine salts, and the like.

[0022] As used herein, the terms "control electronics," "controller," and "processor" refer to any device or facility capable of providing suitable or configurable computing and control capabilities to implement the methods, processes, and techniques described herein, such as, for example, a microprocessor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), equivalent discrete or integrated logic circuitry, or any combination thereof, and capable of providing suitable data storage capabilities, including any medium containing digital bits (e.g., coded in binary, ternary, etc.) that may be readable and writable (e.g., volatile or non-volatile memory, or magnetic recording media such as disks or tapes, etc.).

[0023] The term "aerosol" is used herein to refer to a suspension of solid particles or liquid droplets in a gas, or a combination of solid particles and liquid droplets in a gas. The gas may be air. The solid particles or droplets may include one or more volatile flavor compounds. The aerosol may be visible or invisible. The aerosol may include a vapor of a substance that is normally a liquid or solid at room temperature. The aerosol may include a vapor of a substance that is normally a liquid or solid at room temperature, in combination with solid particles, or in combination with liquid droplets, or in combination with both solid particles and liquid droplets. The aerosol preferably includes nicotine.

[0024] The term "aerosol-generating liquid" is used herein to refer to a liquid capable of releasing one or more volatile compounds capable of forming an aerosol. In some embodiments, the aerosol-generating liquid may be heated to volatilize one or more components of the aerosol-generating liquid and form an aerosol. The aerosol-generating liquid may be referred to as an "e-liquid." The aerosol-generating liquid may be provided as part of an aerosol-generating consumable. The aerosol-generating liquid may be provided within an aerosol-generating consumable.

[0025] The aerosol-generating liquid preferably comprises nicotine. The aerosol-generating liquid may comprise at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of operation 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), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). Preferred aerosol formers are polyhydric alcohols or mixtures thereof (such as triethylene glycol, 1,3-butanediol, and most preferably glycerin). The aerosol-generating liquid may also include other additives and ingredients (such as flavorings).

[0026] The term "aerosol-generating consumable" is used herein to refer to a disposable product that has the ability to contain (e.g., hold, contain, have, or store) an aerosol-generating liquid. The aerosol-generating consumable may have the ability to removably mate or dock with an aerosol-generating device. This allows the aerosol-generating device to generate an aerosol from the aerosol-generating liquid of the aerosol-generating consumable. A "pod" is an example of an "aerosol-generating consumable."

[0027] The term "aerosol-generating device" is used herein to refer to any device configured for use or utilization with an aerosol-generating consumable that emits a volatile compound to form an aerosol that may be inhaled by a user. The aerosol-generating device may be coupled to an aerosol-generating consumable that comprises an aerosol-generating liquid.

[0028] The term "heating element" is used herein to refer to any device, equipment, or portion thereof configured to provide heat or thermal energy to an aerosol-generating consumable to release volatile compounds from the aerosol-generating consumable and form an aerosol.

[0029] The term "thermally conductive polymer element" refers to a thermally sensitive resistor or thermistor, such as a positive temperature coefficient thermistor, which exhibits a significant increase in resistance with increasing temperature. A "thermally conductive polymer element" may be formed of a polymer and optionally a conductive filler.

[0030] The aerosol generating consumable with a fuse element provides overheat protection when used in an aerosol generating system. The aerosol generating consumable includes a heating element having an electrically resistive heating element and a thermally conductive polymer element. The electrically resistive heating element and the thermally conductive polymer element cooperate with control electronics and a power source to form an overheat protection circuit that delivers a current surge to rupture the fuse element when the heating element reaches a predetermined high temperature limit. The predetermined high temperature limit is a temperature above the volatilization temperature of a standard aerosol generating liquid provided in the aerosol generating consumable.

[0031] This high temperature limit may be reached due to depletion of the aerosol-generating liquid within the aerosol-generating consumable. Thus, as the aerosol-generating liquid within the aerosol-generating consumable is consumed, the temperature of the heating assembly, particularly the capillary body, increases as the heat of vaporization energy is no longer transferred into the aerosol-generating liquid.

[0032] This high temperature limit may be reached due to a non-standard aerosol-generating liquid being placed into the aerosol-generating consumable, which may have a higher volatilization temperature than the standard aerosol-generating liquid in the aerosol-generating consumable or the aerosol-generating liquid filled at the time of manufacture. Hence, the temperature of the heating assembly, particularly the capillary body, will increase because the volatilization temperature of the non-standard aerosol-generating liquid or the counterfeit aerosol-generating liquid is higher than the standard aerosol-generating liquid in the aerosol-generating consumable or the aerosol-generating liquid filled at the time of manufacture.

[0033] The aerosol-generating consumable includes a liquid reservoir configured to hold an aerosol-generating liquid and define a liquid outlet opening and a heating assembly secured to the liquid outlet opening. The heating assembly includes a capillary body defining a porous outer surface and an electrically resistive heating element secured to the porous outer surface. The capillary body is configured to cause the aerosol-generating liquid to flow from the liquid outlet opening to the porous outer surface. A thermally conductive polymer element is secured to the porous outer surface. The electrically resistive heating element includes an electrical fuse portion configured to terminate electrical current flow through the resistive heating element.

[0034] Preferably, the thermally conductive polymer element and the resistive heating element are electrically in parallel with each other. Alternatively, the thermally conductive polymer element and the resistive heating element are electrically in series with each other. The thermally conductive polymer element and the resistive heating element may be electrically insulated from each other, but may be configured to be independently electrically connected to the control electronics.

[0035] The electrical fuse portion of the electrically resistive heating element is preferably a portion or region of the resistive wire or trace that forms the electrically resistive heating element, the portion or region of the resistive wire or trace having a reduced width or reduced cross-sectional area that is configured to preferentially melt or rupture the resistive wire or trace when a fusing current is passed through the fuse portion, thereby irreversibly interrupting and stopping the flow of electrical current through the electrically resistive heating element. Upon rupture of the electrical fuse portion, the aerosol-generating consumable is permanently disabled.

[0036] The electrically resistive heating element and the electrical fuse portion may be formed of the same material. The electrically resistive heating element and the electrical fuse portion may be formed of any suitable electrically conductive material, including one or more of a metal, a conductive polymer, or a conductive ceramic.

[0037] Suitable conductive metals include aluminum, silver, nickel, gold, platinum, copper, tungsten and alloys thereof. The conductive metal may preferably be a nickel alloy. The conductive metal may preferably be a nickel iron alloy. The conductive metal may preferably be a nickel chromium iron alloy. The conductive material may comprise a metal powder suspended in a glue such as an epoxy resin. The conductive material may comprise a silver filled epoxy.

[0038] Suitable conductive polymers include PEDOT (poly(3,4-ethylenedioxythiophene)), PSS (poly(p-phenylene sulfide)), PEDOT:PSS (a mixture of both PEDOT and PSS), PANI (polyaniline), PPY (poly(pyrroles)), PPV (poly(p-phenylenevinylene)), or any combination thereof.

[0039] Suitable conductive ceramics include ITO (indium tin oxide), SLT (lanthanum doped strontium titanate), SYT (yttrium doped strontium titanate), or any combination thereof.

[0040] The thermally conductive polymer element is preferably a positive temperature coefficient (PTC) thermistor. In a positive temperature coefficient thermistor, as the temperature increases, the resistance across the thermally conductive polymer element increases. In a positive temperature coefficient thermistor, as the temperature increases, the current across the thermally conductive polymer element decreases.

[0041] The resistance of the thermally conductive polymer element preferably increases substantially at temperature above that of a standard or factory-filled aerosol-generating liquid in the aerosol-generating consumable, and the electrical conductivity or current of the thermally conductive polymer element preferably decreases substantially at temperature above that of a standard or factory-filled aerosol-generating liquid in the aerosol-generating consumable.

[0042] The resistance of the thermally conductive polymer element may increase substantially at temperatures above about 250° C. The electrical conductivity or current of the thermally conductive polymer element may decrease substantially at temperatures above about 250° C.

[0043] The thermally conductive polymer element may have a non-linear resistance or current temperature curve.The thermally conductive polymer element may have a highly non-linear resistance or current temperature curve.The thermally conductive polymer element may have a logarithmic resistance or current temperature curve.

[0044] The thermally conductive polymer element may have a non-linear resistance or current temperature curve at a temperature above that of a standard or factory-prefilled aerosol-generating liquid in the aerosol-generating consumable.The thermally conductive polymer element may have a highly non-linear resistance or current temperature curve at a temperature above that of a standard or factory-prefilled aerosol-generating liquid in the aerosol-generating consumable.The thermally conductive polymer element may have a logarithmic resistance or current temperature curve at a temperature above that of a standard or factory-prefilled aerosol-generating liquid in the aerosol-generating consumable.

[0045] The thermally conductive polymeric element may have a non-linear resistance-temperature curve or current-temperature curve over a temperature range of interest, such as from about 250° C. to about 275° C. The thermally conductive polymeric element may have a highly non-linear resistance-temperature curve or current-temperature curve over a temperature range of interest, such as from about 250° C. to about 275° C. The thermally conductive polymeric element may have a logarithmic resistance-temperature curve or current-temperature curve over a temperature range of interest, such as from about 250° C. to about 275° C.

[0046] The thermally conductive polymeric element may be formed of a suitable polymer selected from polyethylene, polypropylene, polyvinyl acetate, polycaprolactone polyester, syndiotactic polystyrene (sPS), polyamide, poly-tetra-fluoroethylene, polybutylene-terephthalate, polyphenylene-sulfide, high density polyethylene, linear low density polyethylene, low density polyethylene, medium density polyethylene, polyisobutylene, poly(vinylidene chloride), poly(vinylidene fluoride), polyacrylonitrile, polybutadiene, polyethylene-terephthalate, poly(8-aminocaprylic acid), poly(vinyl alcohol), ethylene-based copolymers and terpolymers, maleic anhydride modified polyethylene, glycidyl methacrylate modified grafted polyethylene, maleic anhydride modified polypropylene, glycidyl methacrylate modified polypropylene, or blends, mixtures, or combinations of one or more of these polymers.

[0047] The "thermally conductive polymer element" may be formed of a polymer and a conductive filler. The conductive filler may be dispersed within the polymer matrix. Suitable polymers are listed above. The conductive filler may include carbon particles. The conductive filler may include metal particles. The conductive filler may include metal oxide particles.

[0048] The conductive material from which the heating element is formed may be deposited onto the porous outer surface of the capillary body in any suitable manner, for example, the conductive material from which the heating element is formed may be deposited onto the porous outer surface of the capillary body as a liquid using a dispensing pipette or syringe, or using a fine-tipped transfer device such as a needle.

[0049] The conductive material from which the heating element is formed may be formed of a printable conductive material that may be printed onto the porous outer surface of the capillary body. Any suitable and well-known printing technique may be used, such as one or more of screen printing, gravure printing, flexographic printing, inkjet printing. Such printing processes may be particularly applicable to high speed manufacturing processes.

[0050] The conductive material from which the heating element is formed may be deposited onto the porous outer surface of the capillary body by one or more vacuum deposition processes, such as evaporation and sputtering.

[0051] The conductive material of the thermally conductive polymer element may be deposited onto the porous outer surface of the capillary body in any suitable manner, for example, the conductive material of the thermally conductive polymer element may be deposited onto the porous outer surface of the capillary body as a liquid using a dispensing pipette or syringe, or using a fine-tipped transfer device such as a needle.

[0052] The conductive material of the thermally conductive polymer element may be formed of a printable conductive material that may be printed onto the porous outer surface of the capillary body. Any suitable and well-known printing technique may be used, such as one or more of screen printing, gravure printing, flexographic printing, and inkjet printing. Such printing processes may be particularly applicable to high speed manufacturing processes.

[0053] The conductive material of the thermally conductive polymer element may be deposited onto the porous outer surface of the capillary body by one or more vacuum deposition processes, such as evaporation and sputtering.

[0054] The capillary body may be a capillary wick or other type or shape of capillary body. The capillary body comprises a capillary material. The capillary material may comprise any suitable material or combination of materials. The capillary body may be formed of a single capillary material.

[0055] The capillary material may have a fibrous or spongy structure. The capillary material preferably comprises a bundle of capillaries. For example, the capillary material may comprise a plurality of fibers or threads, or other fine tubes. The fibers or threads may be generally aligned to transport the liquid to the heating element. Alternatively, the capillary material may comprise a spongy or foam-like material. The structure of the capillary material forms a plurality of small holes or tubes through which the liquid can be transported by capillary action. The capillary material(s) may comprise any suitable material or combination of materials. Examples of suitable materials are spongy or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, expanded metal or plastic materials, fibrous materials, such as fibrous materials made of spun or extruded fibers (such as cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics). The capillary material may have any suitable capillarity and porosity to be used with different liquid physical properties. The liquid has physical properties including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure that allow the liquid to be transported through the capillary device by capillary action. The capillary body may preferably be formed of a porous ceramic material and is also referred to as a porous ceramic body.

[0056] The heating assembly may include a first conductive contact portion and a second conductive contact portion in electrical contact with the heating element. The thermally conductive polymer element may be electrically coupled to the first conductive contact portion and the second conductive contact portion. The first conductive contact portion and the second conductive contact portion may be formed of a conductive material that is deposited directly onto the porous outer surface of the capillary body, as described above.

[0057] The heating assembly may include a first conductive contact portion and a second conductive contact portion in electrical contact with the heating element. The thermally conductive polymer element may be electrically coupled to the first conductive contact portion and the third conductive contact portion. The first, second, and third conductive contact portions may be formed of a conductive material that is deposited directly onto the porous outer surface of the capillary body, as described above.

[0058] The heating assembly may include a first conductive contact portion and a second conductive contact portion in electrical contact with the heating element. The thermally conductive polymer element may be electrically coupled to the third conductive contact portion and the fourth conductive contact portion. The first, second, third and fourth conductive contact portions may be formed of a conductive material that is deposited directly onto the porous outer surface of the capillary body, as described above.

[0059] The electrically resistive heating element may be affixed to two sides of the capillary body. A first electrically conductive contact portion is affixed to one of the two sides and a second electrically conductive contact portion is affixed to the remaining one of the two sides. A thermally conductive polymer element may also be affixed to the two sides of the capillary body. Placing both the electrically resistive heating element and the thermally conductive polymer element on the two sides of the capillary body improves the heating uniformity of the capillary body and the temperature sensing capability of the thermally conductive polymer element.

[0060] The electrically resistive heating element may be affixed to three sides of the capillary body. A first electrically conductive contact portion is affixed to one of the three sides and a second electrically conductive contact portion is affixed to one of the two remaining sides. The thermally conductive polymer element may also be affixed to three sides of the capillary body. Placing both the electrically resistive heating element and the thermally conductive polymer element on the three sides of the capillary body further improves the heating uniformity of the capillary body and the temperature sensing capability of the thermally conductive polymer element.

[0061] The electrically resistive heating element preferably defines a curved or serpentine shape on the capillary body and the thermally conductive polymer element defines a linear or rectilinear shape on the capillary body.

[0062] The electrical resistance of the heating element may be between 0.3 and 4 ohms, more preferably between 0.5 and 3 ohms, and even more preferably about 1 ohm.

[0063] The electrically resistive heating element and the thermally conductive polymer element are electrically connected to control electronics in the aerosol generating device when the aerosol generating consumable is mated with the aerosol generating device. The control electronics controls the power supplied to the resistive heating element. The control electronics senses the current flowing through the resistive or thermally conductive polymer element. The control electronics adjusts the power supplied to the resistive heating element and simultaneously senses the current flowing through the resistive or thermally conductive polymer element.

[0064] The aerosol-generating consumables described above mate with an aerosol generating device to form an aerosol generating system. The aerosol-generating consumables are replaceable items within the aerosol generating system. When the aerosol-generating consumables are consumed by a consumer, the depleted aerosol-generating consumable is replaced with a new aerosol-generating consumable having a full aerosol-generating liquid filled by the consumer. Advantageously, the aerosol-generating consumables described above are deactivated when consumed, causing the end of the life of the depleted aerosol-generating consumable.

[0065] The aerosol-generating consumable is removably coupled to the aerosol-generating device. As used herein, an aerosol-generating consumable that is "removably coupled" to an aerosol-generating device means that the aerosol-generating consumable and the aerosol-generating device can be coupled and uncoupled from one another without damaging either the aerosol-generating device or the aerosol-generating consumable.

[0066] The aerosol generating system includes an aerosol generating device and an aerosol generating consumable. The aerosol generating device has a consumable receiving surface including device electrical contacts, a power source, and control electronics electrically connected to the power source and the device electrical contacts. The aerosol generating consumable is configured to mate with the consumable receiving surface and electrically connect the device electrical contacts to the electrically resistive heating element and the thermally conductive polymer element.

[0067] Specifically, the device electrical contacts are electrically connected with the first and second conductive contact portions of the heating assembly when the aerosol-generating consumable is mated with the consumable receiving surface of the aerosol-generating device, and electrical current and sensing signals are conducted between the aerosol-generating device and the aerosol-generating consumable via the device electrical contacts and the first and second conductive contact portions of the heating assembly.

[0068] The control electronics is configured to sense and drive operation of the heating assembly. The control electronics is configured to receive a signal from the thermally conductive polymer element to obtain information of its electrical conductivity. Further, the control electronics is configured to perform an overpowering operation to cause the blowing of the electrical fuse portion in view of the information indicating that a value of the current passing through the thermally conductive polymer element is below a predetermined threshold and indicating that a high temperature threshold has been reached by the heating assembly.

[0069] During normal operation, the control electronics drive the heating assembly such that a heating load is generated to heat the capillary body. Aerosol-generating liquid stored in the liquid reservoir permeates into the capillary body and is then heated by the heating assembly to become a vapor. As the user inhales, the vapor is drawn from the vaporizer into the user's mouth.

[0070] The operating temperature range of the heating assembly may be within a range of about 200° C. to about 250° C. When an aerosol-generating liquid is present within the capillary body and undergoes thermal depletion based on a phase transition, the temperature of the capillary body remains continuously within this operating temperature range.

[0071] On the other hand, if no aerosol-generating liquid is present within the capillary body, the temperature of the capillary body will increase, decreasing the electrical conductivity of the thermally conductive polymer element. The control electronics receive this signal from the thermally conductive polymer element indicative of the value of the current passing through the thermally conductive polymer element to determine whether the real-time value is below a predetermined threshold. If so, the control electronics automatically executes an overpowering operation or a blowing current to the electrical fuse portion of the electrically resistive heating element. The control electronics may be configured to deliver a blowing current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element. The control electronics may be configured to deliver a blowing current to the electrical fuse portion in response to sensing a high threshold resistance value across the thermally conductive polymer element. As a result, irreversible break in the electrical circuit causes the end of life of the heating assembly and the aerosol-generating consumable.

[0072] The control electronics may be configured to deliver a blow current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of about 275° C. The control electronics may be configured to deliver a blow current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of about 265° C. The control electronics may be configured to deliver a blow current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of about 260° C. The control electronics may be configured to deliver a blow current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of about 255° C. The control electronics may be configured to deliver a blow current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of about 251° C.

[0073] The aerosol generating device may include a controller or control electronics with one or more processors (e.g., microprocessors). The one or more processors may operate with associated data storage or memory to access processing programs or routines and one or more types of data that may be employed to perform the exemplary methods. For example, the processing programs or routines stored in the data storage may include programs or routines for controlling or sensing the heating element and the thermally conductive polymer element, individually controlling the heating assembly, implementing a program or scheme using one or more of the heating element and the thermally conductive polymer element, and the like.

[0074] The control electronics may comprise a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated circuit chip (ASIC) or other electronic circuitry capable of providing control. The control electronics may comprise additional electronic components. The control electronics may be configured to regulate the supply of power to the heater assembly. Power may be supplied to the heater assembly continuously after activation of the system, or may be supplied intermittently (such as with every puff). Power may be supplied to the heater assembly in the form of power pulses.

[0075] The aerosol generating device includes a power source for the heater assembly of the aerosol generating consumable. The power source may be a battery within the device, such as a lithium iron phosphate battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows for storage of sufficient energy for one or more smoking experiences. For example, the power source may have a capacity sufficient to allow continuous generation of aerosol for approximately six minutes, which corresponds to the typical time it takes to smoke one conventional cigarette, or a multiple of six minutes. In another embodiment, the power source may have a capacity sufficient to allow for a predetermined number of puffs, or discontinuous activation of the heater.

[0076] The computer program product used to implement the processes described herein may be provided using any programmable language, such as a high-level procedural or object-oriented programming language suitable for communicating with a computer system. Any such program product may be stored, for example, on any suitable device, such as a storage medium readable by a general-purpose or special-purpose program, a controller device for configuring and operating a computer when read by a suitable device to perform the procedures described herein. In other words, in at least one embodiment, the aerosol generating device may be implemented using a non-transitory computer-readable storage medium configured with a computer program, the storage medium so configured causing a computer to operate in a specific and predefined manner to perform the functions described herein.

[0077] The exact configuration of the controller of the aerosol generating device is not limited, and essentially any device capable of providing suitable computing and control capabilities to perform the method may be used. In view of the above, it is readily apparent that functionality may be implemented in any manner, as would be known to one of ordinary skill in the art. Thus, the computer language, controller, or any other software / hardware used to perform the processes described herein should not be limited in scope to the systems, processes, or programs described herein (e.g., the functionality provided by such processes or programs). The methods and processes described herein, including those resulting from the system, or various components, may be implemented at least in part in hardware, software, firmware, or any combination thereof. For example, various embodiments of the techniques may be implemented within one or more processors, including one or more microprocessors, DSPs, ASICs, FPGAs, CPLDs, microcontrollers, or any other equivalent integrated or discrete logic circuits, as well as any combination of such components. When implemented in software, the functions of the systems, apparatus, and methods described in this disclosure may be embodied as instructions on a computer-readable medium, such as a RAM, a ROM, a NVRAM, an EEPROM, a FLASH memory, a magnetic data storage medium, an optical data storage medium, or the like. The instructions may be executed by one or more processors to support one or more embodiments of the functions.

[0078] 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 the other examples, embodiments, or aspects described herein. EXAMPLES

[0079] [Example 1] An aerosol-generating consumable comprising a liquid reservoir configured to hold an aerosol-generating liquid and define a liquid outlet opening and a heating assembly secured to the liquid outlet opening. The heating assembly comprises a capillary body defining a porous outer surface, the capillary body configured to direct the aerosol-generating liquid from the liquid outlet opening to the porous outer surface, an electrically resistive heating element secured to the porous outer surface, and a thermally conductive polymeric element secured to the porous outer surface. The electrically resistive heating element comprises an electrical fuse portion configured to terminate electrical current passing through the electrically resistive heating element.

[0080] [Example 2] The aerosol-generating consumable of Example 1, wherein the thermally conductive polymer element is a positive temperature coefficient thermistor comprising a polymer and a conductive filler.

[0081] [Example 3] The aerosol-generating consumable according to any preceding embodiment, wherein the thermally conductive polymer element and the electrically resistive heating element are electrically in parallel with each other.

[0082] [Example 4] The aerosol-generating consumable according to any preceding embodiment, wherein the thermally conductive polymer element and the electrically resistive heating element are in electrical series with each other.

[0083] [Example 5] The aerosol-generating consumable according to any preceding embodiment, wherein the electrical fuse portion defines a reduced cross-sectional area compared to a remainder of the electrically resistive heating element.

[0084] [Example 6] The aerosol-generating consumable according to any preceding embodiment, wherein the capillary body is a porous ceramic body.

[0085] [Example 7] An aerosol-generating consumable according to any preceding embodiment, wherein an electrically resistive heating element is fixed to two sides of the capillary body.

[0086] [Example 8] An aerosol-generating consumable according to any preceding embodiment, wherein an electrically resistive heating element is fixed to three sides of the capillary body.

[0087] [Example 9] An aerosol-generating consumable according to any preceding embodiment, wherein the thermally conductive polymer element is secured to two sides of the capillary body.

[0088] [Example 10] An aerosol-generating consumable according to any preceding embodiment, wherein the thermally conductive polymer element is secured to three sides of the capillary body.

[0089] [Example 11] An aerosol-generating consumable according to any preceding embodiment, wherein the electrically resistive heating element defines a curvilinear or serpentine shape and the thermally conductive polymer element defines a linear or rectilinear shape.

[0090] [Example 12] An aerosol generation system comprising an aerosol generation device comprising a consumable receiving surface, the consumable receiving surface including device electrical contacts, a power source, and control electronics electrically connected to the power source and to the device electrical contacts, The aerosol generation system further includes an aerosol-generating consumable according to any preceding embodiment configured to mate with the consumable receiving surface and electrically connect the device electrical contacts to the electrically resistive heating element and the thermally conductive polymer element.

[0091] [Example 13] An aerosol generation system according to Example 12, wherein the control electronics is configured to sense the current across the thermally conductive polymer element.

[0092] [Example 14] An aerosol generating system according to Example 12 or Example 13, wherein the control electronics is configured to deliver a fusing current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element.

[0093] [Example 15] An aerosol generation system according to Examples 12 to 14, wherein the control electronics is configured to deliver a fusing current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of approximately 275°C.

[0094] [Example 16] An aerosol generation system according to Examples 12 to 14, wherein the control electronics is configured to deliver a fusing current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of approximately 265°C.

[0095] [Example 17] An aerosol generation system according to Examples 12 to 14, wherein the control electronics is configured to deliver a fusing current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of approximately 260°C.

[0096] [Example 18] An aerosol generation system according to Examples 12 to 14, wherein the control electronics is configured to deliver a fusing current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of approximately 255°C.

[0097] [Example 19] A method for disabling an aerosol-generating consumable heating element, comprising: providing an aerosol generating system according to any one of Examples 12 to 18; heating an aerosol-generating liquid using the heating element to form an aerosol; sensing current across a thermally conductive polymer element on the heating element using control electronics; and delivering a fusing current to an electrically resistive electrical fuse portion of the heating element in response to the sensed low threshold current value across the thermally conductive polymer element.

[0098] [Example 20] A method of disabling a heating element of an aerosol-generating consumable according to Example 19, wherein the delivering step includes sensing a low threshold current value corresponding to a capillary body temperature of about 275°C.

[0099] [Example 21] A method of disabling a heating element of an aerosol-generating consumable according to Example 16, wherein the delivering step includes sensing a low threshold current value corresponding to a capillary body temperature of about 265°C.

[0100] [Example 22] A method of disabling a heating element of an aerosol-generating consumable according to Example 16, wherein the delivering step includes sensing a low threshold current value corresponding to a capillary body temperature of about 260°C.

[0101] [Example 23] A method of disabling a heating element of an aerosol-generating consumable according to Example 16, wherein the delivering step includes sensing a low threshold current value corresponding to a capillary body temperature of about 255°C.

[0102] The embodiments will now be further described with reference to the figures. [Brief description of the drawings]

[0103] [Figure 1] FIG. 1 is a schematic diagram of an exemplary aerosol generation system. [Diagram 2] FIG. 2 is a schematic diagram of an exemplary aerosol-generating consumable that generates an aerosol. [Diagram 3] FIG. 3 is a schematic diagram of an exemplary deactivated aerosol-generating consumable. [Figure 4A] FIG. 4A is a schematic diagram of an exemplary electrical fuse portion of an electrically resistive heating element. [Figure 4B] FIG. 4B is a schematic diagram of an exemplary electrical fuse portion of an electrically resistive heating element after application of a fusing current. [Diagram 5]FIG. 5 is a schematic diagram of an exemplary aerosol-generating consumable having an electrically resistive heating element and a thermally conductive polymer element affixed to two sides of a capillary body. [Figure 6] FIG. 6 is a schematic diagram of an exemplary aerosol-generating consumable having an electrically resistive heating element and a thermally conductive polymer element affixed to three sides of a capillary body. [Figure 7] FIG. 7 is a schematic diagram of an exemplary control circuit and heating assembly. [Figure 8] FIG. 8 is a schematic diagram of another exemplary control circuit and heating assembly. [Figure 9] FIG. 9 is a schematic diagram of another exemplary control circuit and heating assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0104] The schematic diagrams are not necessarily to scale and are presented for purposes of illustration, not limitation. The drawings illustrate one or more aspects described in the present disclosure. However, it will be understood that other aspects not shown in the drawings fall within the scope and spirit of the present disclosure.

[0105] 1 is a schematic diagram of an exemplary aerosol generating system 100. The aerosol generating system 100 comprises an aerosol generating device 110 and an aerosol generating consumable 120. The aerosol generating device 110 comprises a consumable receiving surface 112. The consumable receiving surface 112 includes device electrical contacts 114. The aerosol generating device 110 also comprises a power source 118 and control electronics 116 electrically connected to the power source 118 and the device electrical contacts 114. The aerosol generating consumable 120 is configured to mate with the consumable receiving surface 112 and electrically connect the device electrical contacts 114 with an electrically resistive heating element and a thermally conductive polymer element contained within the aerosol generating consumable 120. The aerosol generating consumable 120 may include a mouthpiece 12.

[0106] Figure 2 is a schematic diagram of an exemplary aerosol-generating consumable 120 that generates an aerosol 101. Figure 3 is a schematic diagram of an exemplary deactivated aerosol-generating consumable 120 that generates a burning odor 106.

[0107] The aerosol-generating consumable 120 comprises a liquid reservoir 122 configured to hold an aerosol-generating liquid 121 and defining a liquid outlet opening 124. A heating assembly 130 is secured to the liquid outlet opening 124. The heating assembly 130 comprises a capillary body 132 defining a porous outer surface 133. The capillary body 132 is configured to direct the aerosol-generating liquid 121 from the liquid outlet opening 124 to the porous outer surface 133. An electrically resistive heating element 140 is secured to the porous outer surface 133. A thermally conductive polymer element 150 is secured to the porous outer surface 133. The electrically resistive heating element 140 includes an electrical fuse portion 145 configured to terminate electrical current flow through the resistive heating element.

[0108] The thermally conductive polymer element 150 and the electrically resistive heating element 140 are electrically in parallel with each other. The thermally conductive polymer element 150 and the electrically resistive heating element 140 are in electrical contact with the first and second conductive contact portions 134, 135. The first and second conductive contact portions 134, 135 electrically connect with the device electrical contacts 114 of the aerosol generating device 110.

[0109] 3 illustrates a depleted aerosol-generating consumable 120 having an empty liquid reservoir 122. The electrical fuse portion 145 is illustrated as being in a "blown" or open configuration following application of a fusing current to the electrical fuse portion 145.

[0110] Figure 4A is a schematic diagram of an exemplary electrical fuse portion 145 of electrically resistive heating element 140. Figure 4B is a schematic diagram of an exemplary electrical fuse portion 143 of electrically resistive heating element 140 after application of a fusing current. Electrical fuse portion 145 defines a reduced width or cross-sectional area as compared to the remainder of electrically resistive heating element 140.

[0111] 5 is a schematic diagram of an exemplary aerosol-generating consumable 120 having an electrically resistive heating element 140 and a thermally conductive polymer element 150 secured to two sides 136, 137 of a capillary body 132. The electrically resistive heating element 140 defines a curvilinear or serpentine shape, and the thermally conductive polymer element 150 defines a linear or rectilinear shape along the surfaces of the two sides 136, 137 of the capillary body 132.

[0112] 6 is a schematic diagram of an exemplary aerosol-generating consumable 120 having an electrically resistive heating element 140 and a thermally conductive polymer element 150 secured to three sides 136, 137, 138 of a capillary body 132. The electrically resistive heating element 140 defines a curvilinear or serpentine shape, and the thermally conductive polymer element 150 defines a linear or rectilinear shape along the surfaces of the three sides 136, 137, 138 of the capillary body 132.

[0113] 7 is a schematic diagram of an exemplary control circuit and heating assembly 130. The heating assembly 130 is disposed on an outer surface 133 of a capillary body 132. The heating assembly 130 includes an electrically resistive heating element 140 and an electrical fuse portion 145 electrically insulated from a thermally conductive polymer element 150. The electrically resistive heating element 140 is in electrical contact with a first conductive contact portion 134, 135 and a second conductive contact portion 134, 135. The first conductive contact portion 134, 135 are electrically connected to the control electronics 116. The thermally conductive polymer element 150 is in electrical contact with a third conductive contact portion 151, 152 and a fourth conductive contact portion 151, 152. The third conductive contact portion 151, 152 are electrically connected to the control electronics 116.

[0114] 8 is a schematic diagram of another exemplary control circuit and heating assembly 130. The heating assembly 130 is disposed on an outer surface 133 of a capillary body 132. The heating assembly 130 includes an electrically resistive heating element 140 and an electrical fuse portion 145 in electrical parallel with a thermally conductive polymer element 150. The electrically resistive heating element 140 is in electrical contact with a first conductive contact portion 134, 135. The first conductive contact portion 134, 135 is electrically connected to the control electronics 116. The thermally conductive polymer element 150 is in electrical contact with a first conductive contact portion 134, 151 and a third conductive contact portion 134, 151. The first conductive contact portion 134, 151 is electrically connected to the control electronics 116.

[0115] 9 is a schematic diagram of another exemplary control circuit and heating assembly 130. The heating assembly 130 is disposed on an outer surface 133 of a capillary body 132. The heating assembly 130 includes an electrically resistive heating element 140 and an electrical fuse portion 145 in electrical parallel with a thermally conductive polymer element 150. The electrically resistive heating element 140 is in electrical contact with a first conductive contact portion 134, 135. The first conductive contact portion 134, 135 is electrically connected to the control electronics 116. The thermally conductive polymer element 150 is in electrical contact with a first conductive contact portion 134, 151 and a third conductive contact portion 134, 151. The first conductive contact portion 134, 151 is electrically connected to the control electronics 116.

[0116] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances 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±2%. Within this context, the number A may be considered to include values ​​that are within the typical standard error for the measurement of the property that the number A modifies. The number A may, in some cases as used in the appended claims, deviate by the percentages recited above, provided that the amount by which A deviates does not substantially affect the basic and novel property(ies) 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. An aerosol-generating consumable product comprising: a liquid reservoir configured to hold an aerosol-generating liquid and defining a liquid outlet opening; a heating assembly secured to the liquid outlet opening, a capillary body defining a porous outer surface, the capillary body configured to direct aerosol-generating liquid from the liquid outlet opening to the porous outer surface; an electrically resistive heating element secured to the porous outer surface; a thermally conductive polymer element secured to the porous outer surface; a heating assembly, wherein the electrically resistive heating element comprises an electrical fuse portion configured to terminate electrical current flow through the electrically resistive heating element.

2. 10. The aerosol-generating consumable product of claim 1, wherein the thermally conductive polymer element is a positive temperature coefficient thermistor comprising a polymer and a conductive filler.

3. 10. The aerosol-generating consumable product of claim 1, wherein the thermally conductive polymer element and the electrically resistive heating element are electrically parallel to each other.

4. 10. The aerosol-generating consumable product of claim 1, wherein the thermally conductive polymer element and the electrically resistive heating element are electrically in series with each other.

5. The aerosol-generating consumable of claim 1 , wherein the electrical fuse portion defines a reduced cross-sectional area compared to the remainder of the electrically resistive heating element.

6. The aerosol-generating consumable product of claim 1 , wherein the capillary body is a porous ceramic body.

7. 2. The aerosol-generating consumable of claim 1, wherein the electrically resistive heating element is fixed to two sides of the capillary body, or the electrically resistive heating element is fixed to three sides of the capillary body.

8. 10. The aerosol-generating consumable of claim 1, wherein the thermally conductive polymer element is fixed to two sides of the capillary body, or the thermally conductive polymer element is fixed to three sides of the capillary body.

9. 10. The aerosol-generating consumable product of claim 1, wherein the electrically resistive heating element defines a curved or serpentine shape and the thermally conductive polymer element defines a linear or rectilinear shape.

10. 1. An aerosol generating system comprising: An aerosol generating device, comprising: a consumable receiving surface including device electrical contacts; Power supply and an aerosol generating device comprising control electronics electrically connected to the power source and the device electrical contacts; an aerosol-generating consumable according to claim 1 configured to mate with the consumable receiving surface and electrically connect the device electrical contacts with the electrically resistive heating element and the thermally conductive polymer element;

11. 11. The aerosol generating system of claim 10, wherein the control electronics is configured to sense the current across the thermally conductive polymer element.

12. 11. The aerosol generating system of claim 10, wherein the control electronics is configured to deliver a fusing current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element.

13. 11. The aerosol generation system of claim 10, wherein the control electronics is configured to deliver a fusing current to the electrical fuse portion in response to sensing a low threshold current value across the thermally conductive polymer element corresponding to a capillary body temperature of about 275°C, or about 265°C, or about 260°C, or about 255°C.

14. 1. A method for deactivating an aerosol-generating consumable heating element, comprising: Providing an aerosol generating system according to claim 10; heating the aerosol-generating liquid using the heating element to form an aerosol; sensing the current across the thermally conductive polymer element on the heating element with the control electronics; delivering a fusing current to the electrically resistive heating element electrical fuse portion in response to a sensed low threshold current value across the thermally conductive polymer element.

15. 15. The method of claim 14, wherein delivering comprises sensing a low threshold current value corresponding to a capillary body temperature of about 275°C, or about 265°C, or about 260°C, or about 255°C.

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