Cartridge for aerosol generation system

Abstract

To provide a cartridge for use in an aerosol generation system.SOLUTION: The cartridge includes a liquid storage portion including a housing (24) for holding a liquid aerosol forming base substance, the liquid storage portion including at least two portions in fluid communication with each other. A first portion (32) of the liquid storage portion includes a heater assembly (46), a first capillary material (36) provided in contact with the heater assembly, and a second capillary material (38) in contact with the first capillary material and spaced from the heater assembly by the first capillary material. A second portion (34) of the liquid storage portion includes a container (e.g., a tank) for holding the liquid aerosol forming base substance and supplies a liquid to the second capillary material.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to an aerosol generating system. In particular, the present invention relates to a handheld aerosol generating system, such as an electrically operated smoking system. Aspects of the present invention relate to a cartridge for an aerosol generating system, in particular for an electrically operated smoking system.

Background Art

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

[0003] In some types of electrically operated aerosol generating devices, a reservoir of the aerosol forming liquid is provided within a tank. When used within the aerosol generating system, the liquid is transported by capillary action from the tank to the wick of the coil wick heater assembly, where the liquid is vaporized. When the user sucks on the mouthpiece, an air flow passes through the heater assembly and the generated aerosol is inhaled by the user.

[0004] A problem with such tank devices is that the system stops generating aerosol when the device is held at an angle such that the liquid aerosol generating substrate within the tank does not contact the capillary system. Moreover, these systems may tend to leak, for example, if liquid from the tank floods the core or leaks through the air flow path.

[0005] In other systems, the liquid storage portion of the cartridge is filled with a capillary medium. The liquid aerosol generating substrate is held within the capillary material and delivered to the wick. In such systems, the problems of the holding angle and risk of leakage mentioned above can be reduced. However, some residual liquid remains in the capillary material after use, which is wasteful. Further, in the smoking delivery of such systems, the consistency may be lost due to the decrease in the saturation of the capillary medium during use, which does not allow a certain high-quality smoking experience.

[0006] It is desirable to have a cartridge that avoids one or more of the disadvantages mentioned above or otherwise, for example, avoids waste of the aerosol generating substrate liquid, and at the same time, it is preferable that the aerosol generating performance of the aerosol generating system in which the cartridge is used is maintained or improved. SUMMARY OF THE INVENTION

[0007] According to a first aspect of the present invention, there is provided a cartridge for use in an aerosol generating system, including a liquid storage portion for holding a liquid aerosol forming substrate, for example, an electrically operated aerosol generating system. The liquid storage portion includes at least two portions in fluid communication with each other. The first portion of the liquid storage portion includes a heater assembly, a first capillary material provided in contact with the heater assembly, and a second capillary material in contact with the first capillary material and spaced from the heater assembly by the first capillary material. The second portion of the liquid storage portion preferably includes a container for holding the liquid aerosol forming substrate and is arranged to supply liquid to the second capillary material. The second portion of the liquid storage portion may be substantially empty and comprise a tank suitable for holding the liquid aerosol forming substrate.

[0008] The capillary material is preferably designed to have the ability to hold a sufficient liquid matrix for several smoking sessions. Since the capillary material is located in contact with the heater, the heater is provided independently of the holding angle of the aerosol-generating liquid having a sufficient amount of aerosol-generating liquid. The remaining internal volume of the liquid storage portion does not contain the capillary material and represents an empty tank for storing the aerosol-generating liquid. Under normal handling conditions, the aerosol-generating medium, particularly the aerosol-generating smoking device, is moved during a smoking session, and the capillary material regularly contacts and re-absorbs the fresh aerosol-generating liquid.

[0009] Since a small amount of capillary material is used, the amount of residual liquid remaining in the capillary material after use of the cartridge is less than that of a conventional cartridge in which the entire liquid storage portion is filled with the capillary material. Moreover, in performance tests, the TPM (total particulate matter) yield of the aerosol-generating smoking device equipped with the cartridge of the present invention has been shown to be comparable to the performance of the aerosol-generating smoking device equipped with cartridges currently available in many cases.

[0010] The liquid capacity of the capillary material is preferably such that it can hold sufficient liquid for 30 to 40 or more smoking sessions. A 3-second puff can contain about 1 mg to 4 mg of liquid, for example 3 mg to 4 mg of liquid. The capacity of the capillary material is preferably between about 30 mg and about 160 mg, more preferably 90 mg to about 160 mg or more, or 100 mg to 150 mg, for example 130 mg. If there are two layers constituting the capillary material, the capacities of the first and second layers are such that about 10 to 20 weight percent of the liquid capacity is in the first layer. For example, if the capacity of the capillary material is for 30 smoking sessions, the capacity of the first layer can be for about 5 smoking sessions, and the capacity of the second layer can be for about 25 smoking sessions.

[0011] Without being bound by any particular theory, it is believed that the risk of leakage from the device is reduced by a capillary material having a dosage equivalent to several puffs of smoking (for example, 30 or more puffs). If the capillary material is too small, during smoking, the liquid may be directly drawn through the capillary material and the heater without being vaporized from the reservoir, which may lead to leakage. Also, by having a capacity of 90 mg or more, it is possible to take out a number of puffs from the device even when the liquid in the reservoir is not in direct contact with the capillary material.

[0012] The heater assembly can be substantially planar and can include a conductive filament, and does not require any winding around the capillary core with a heater wire at all.

[0013] The conductive filament can be located within a single plane. The planar heater assembly can be easily handled during manufacturing and provides a robust structure.

[0014] The conductive filament can define gaps between the filaments, and the width of the gaps can be from 10 μm to 100 μm. The filaments can cause capillary action within the gaps such that the liquid that will be vaporized during use is drawn into the gaps, increasing the contact area between the heater assembly and the liquid.

[0015] The conductive filament can form a mesh sized 160 - 600 mesh US (±10%) (that is, the number of filaments per inch is 160 - 600 (±10%)). The width of the gaps is preferably from 75 μm to 25 μm. The area ratio of the gaps to the total area of the mesh, which is the area ratio of the openings of the mesh, is preferably from 25% to 56%. The mesh may be formed using different types of woven or lattice structures. Alternatively, the conductive filament is composed of a series of filaments arranged parallel to each other.

[0016] The diameter of the conductive filament can be 10 μm to 100 μm, preferably 8 μm to 50 μm, and more preferably 8 μm to 39 μm. The filament may have a round cross-section or a flat cross-section. The heater filament can be formed by etching a sheet material (such as a foil). This can be particularly advantageous when the heater assembly includes a series of parallel filaments. When the heater assembly includes a mesh or a woven fabric of filaments, the filaments can be formed individually and woven together.

[0017] As described in connection with the first aspect, the heater assembly can include at least one filament made of a first material and at least one filament made of a second material different from the first material.

[0018] The heater assembly can include an electrically insulated substrate on which the filaments are supported, and the filaments extend across openings formed in the substrate. The electrically insulated substrate can be made of any suitable material, but is preferably a material that can withstand high temperatures (above 300 degrees Celsius) and rapid temperature changes. An example of a suitable material is a polyimide film such as Kapton (registered trademark).

[0019] The heater assembly can include conductive contacts in contact with a plurality of filaments. The conductive contacts can be provided between the housing of the liquid storage portion and the electrically insulated substrate. The conductive contacts can be provided between the filaments and the electrically insulated substrate. The openings can be formed in an insulating layer, and the cartridge can include two conductive contacts located on opposite sides of the openings from each other.

[0020] The capillary material is preferably a material that actively transports the liquid from one end of the material to the other. The capillary material is advantageously directed to transport the liquid to the heater assembly within the housing.

[0021] The second capillary material may have a fibrous structure, where the fibers are generally oriented in the direction of movement of the liquid into the heater. The first capillary material may have less oriented fibers. For example, the first capillary material may have a felt structure.

[0022] The capillary material may have a fibrous or sponge-like structure. The capillary material preferably includes a bundle of capillaries. For example, the capillary material may include a plurality of fibers or threads, or other fine tubes. The fibers or threads may generally be aligned to move liquid to the heater. Alternatively, the capillary material may include a sponge-like or foam-like material. The structure of the capillary material forms a number of small holes or tubes through which liquid can move by capillary action. The capillary material may include any suitable material or combination of materials. Examples of suitable materials include sponge or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, foamed metals or plastic materials, such as fibrous materials made of spun or extruded fibers (cellulose acetate, polyester, or bonded polyolefins, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics, etc.). The capillary material may have any suitable capillary 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 move through the capillary device by capillary action.

[0023] The capillary material may contact a heater, such as a conductive filament. The capillary material may extend into the gaps between the filaments. The heater assembly may draw the liquid aerosol-forming substrate into the gaps by capillary action. The capillary material may contact the conductive filament substantially over the entire length of the opening.

[0024] The housing may include two or more different capillary materials. Here, the first capillary material in contact with the heater element has a higher thermal decomposition temperature, and the second capillary material in contact with the first capillary material but not in contact with the heater element has a lower thermal decomposition temperature. The first capillary material effectively serves as a spacer to separate the heater element from the second capillary material so that the second capillary material is not exposed to a temperature exceeding its thermal decomposition temperature. As used herein, "thermal decomposition temperature" means the temperature at which a material begins to decompose and loses mass by generating gaseous by-products. The second capillary material may advantageously occupy a larger volume than the first capillary material and may also hold more aerosol-forming substrate than the first capillary material. The second capillary material may have better wicking performance than the first capillary material. The second capillary material may be less expensive than the first capillary material. The second capillary material may be polypropylene.

[0025] The first capillary material can be selected from the group consisting of Kevlar felt, ceramic paper, ceramic felt, carbon felt, cellulose acetate, hemp felt, PET / PBT sheet, cotton pad, porous ceramic disk or porous metal disk.

[0026] Preferred materials include Kevlar felt, ceramic paper, ceramic felt, porous ceramic disk or porous metal disk. The first capillary material may comprise glass fiber paper or felt. Preferably, the first capillary material is substantially free of organic matter.

[0027] The porosity of the first capillary material is preferably smaller than that of the second capillary material. The pore size of the first capillary material is preferably smaller than the porosity of the second capillary material. The pore size can be measured, for example, as the average pore size for the region of the capillary material. By doing so, it can be seen that the aerosol generation substrate moves to the heater more efficiently. In a broad aspect of the present invention, a cartridge is provided that includes a heater and a capillary material in contact with the heater for supplying an aerosol generation substrate to the heater, where the porosity or pore size of the region of the capillary material adjacent to the heater is smaller than the porosity or pore size of the region of the capillary material away from the heater. Thus, a single material, for example, one having a pore size gradient in one or more of its dimensions, can be used.

[0028] The first capillary material can have a fiber size / pore size of 0.1 to 50 μm, preferably 0.5 to 10 μm, and most preferably about 4 μm. The first capillary material has a density of less than 2 g / ml, preferably about 0.5 g / ml.

[0029] The second capillary material can be a so-called high-retention material (HRM) selected from the group of polypropylene (PP), polyethylene (PE), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), a rolled nonwoven material, or a rolled felt. The second capillary material preferably includes a polymer material. The material can include a coating, for example, to reduce hydrophobicity.

[0030] The second capillary material can have a fiber size / pore size of 1 to 100 μm, preferably 15 to 40 μm, and most preferably about 25 μm. The second capillary material has a density of less than 1 g / ml, preferably 0.1 to 0.3 g / ml.

[0031] The first capillary material can separate the heater assembly from the second capillary material by a distance of at least 0.8 mm (at least 1.5 mm), and is preferably 0.8 mm to 2 mm in order to provide a sufficient temperature drop across the first capillary material.

[0032] The first and second capillary materials can also be made of the same material and can be distinguished from each other only in terms of showing different porosities or different capillarity. For example, the first capillary material can be compressed such that its pore size or porosity is reduced and its capillarity is increased as compared to the second capillary material which can be used in an uncompressed or at least less compressed state.

[0033] In one preferred embodiment, the first and second materials are made from a single continuous element of the same base material. The material is preferably processed such that the pore size or porosity gradient is directed in the direction towards the heater element or the opening, for example decreasing continuously, such that the pore size or porosity decreases towards the heater element within the capillary material.

[0034] Preferably, at least the first capillary material is compressed after insertion into the first part of the housing of the liquid storage portion such that its effective pore size or porosity is reduced. For example, the single continuous element can have the shape of a truncated cone, where the diameter of the circular base of the truncated cone is larger than the inner diameter of the cylindrical housing of the liquid storage portion, while the diameter of the truncated tip of the cone substantially corresponds to the inner diameter of the cylindrical housing of the liquid storage portion. After insertion, the capillary material at the base of the cone of the capillary material is more compressed than in the region of the truncated tip. The more compressed material represents the first capillary material and the less compressed material represents the second capillary material. One skilled in the art will readily understand that the resulting compression gradient depends on the relative shapes selected for the capillary element and the housing of the liquid storage portion.

[0035] In a particularly preferred embodiment, the capillary element has a regular cylindrical shape with a circular cross-section and a predetermined diameter. The inner surface of the housing includes a tapered portion at the open end such that the capillary material is compressed by its tapered portion after the capillary material is inserted into the housing. The inner surface of the housing preferably has a conical shape such that the inner diameter continuously increases from the open end to the closed end of the cartridge.

[0036] The first capillary material and the second capillary material may include different regions of the same capillary material element. When incorporated within the housing, the compression of the capillary material may be performed such that the pore size or porosity of the capillary material decreases or continuously decreases towards the heater assembly.

[0037] In a further embodiment, the first and second capillary materials are also formed from a single continuous piece of the same material. The capillary material can be a rectangular web of capillary material having a thickness of less than 50%, preferably about 25% of the inner diameter of the cylindrical housing of the cartridge. The width of the web of capillary material corresponds to the peripheral outer circumference of the housing. The web of capillary material can have any desired length, preferably about half the length of the housing of the cartridge. The web of capillary material is wound to form a cylindrical shape. By winding, the central portion of the web is compressed to a greater degree than the outer portion of the web so that a gradient of pore size or porosity is obtained in the radial direction of the wound web of capillary material. An air channel is formed in the center of the wound capillary material. A tubular fluid-permeable heater element is provided within the air channel such that the heater is in direct contact with the inner surface of the wound capillary material. When the capillary material is wound, the portion of the material closer to the central axis of the cylinder is compressed more than the material located radially outward of the capillary material. Thus, again a gradient of pore size is obtained, where the pore size of the capillary material decreases continuously in the direction of the heater element within the capillary material. The capillary material is in fluid communication with a liquid reservoir, where the liquid reservoir is provided within a portion of the housing not occupied by the capillary material. A partition is provided within the housing so that the liquid matrix is not in direct communication with the air flow channel.

[0038] The web of capillary material can also comprise multiple layers of capillary material so that the liquid holding properties of the capillary material can be designed in any desired manner most appropriate for a given aerosol generating system.

[0039] In a particular preferred embodiment, the heater element is wound together with the capillary material so that in only one manufacturing step, an integral capillary material with a radial gradient and a heating element is obtained.

[0040] The liquid storage portion is located on a first side of the conductive filament such that an air flow passing through the conductive filament is mixed into the vaporized liquid aerosol forming substrate, and the air flow channel can be located in the liquid storage portion from the opposite side of the conductive filament.

[0041] The aerosol generating system preferably includes a housing. The housing is preferably elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications such as, for example, polypropylene, polyetheretherketone (PEEK) and polyethylene. The material is preferably lightweight and not brittle. The material may include PET, PBT or PPS.

[0042] The aerosol generating system is preferably portable. The aerosol generating system can have a size comparable to that of a conventional cigar or cigarette. The overall length of the smoking system can be approximately 30 mm to approximately 150 mm. The outer diameter of the smoking system can be approximately 5 mm to approximately 30 mm.

[0043] The aerosol forming substrate is a substrate having the ability to release a volatile compound capable of forming an aerosol. The volatile compound can be released by heating the aerosol forming substrate.

[0044] The aerosol forming substrate may include a plant-derived material. The aerosol forming substrate may include tobacco. The aerosol forming substrate may include a tobacco-containing material that includes volatile tobacco flavor compounds released from the aerosol forming substrate upon heating. Alternatively, the aerosol forming substrate may include a non-tobacco-containing material. The aerosol forming substrate may include a homogenized plant-derived material. The aerosol forming substrate may include a homogenized tobacco material. The aerosol forming substrate may optionally include at least one aerosol forming agent. The aerosol forming substrate may include other additives and components (such as flavorants).

[0045] The liquid storage portion includes an opening, and the heater assembly preferably extends across the opening of the housing. The heater assembly may comprise an electrically insulated substrate on which the heater element is supported. The electrically insulated substrate may comprise any suitable material, but is preferably a material that can withstand high temperatures (above 300 degrees Celsius) and rapid temperature changes. An example of a suitable material is a polyimide film such as Kapton®. The electrically insulated substrate can have an opening formed therein, and the heater element extends across the opening. The heater assembly may comprise an electrical contact connected to a conductive filament.

[0046] According to a second aspect of the present invention, there is provided a cartridge for use in an aerosol generating system comprising a liquid storage portion including a housing for holding a liquid aerosol-forming substrate, for example an electrically operated aerosol generating system, wherein the liquid storage portion includes at least two portions in fluid communication with each other. The first portion of the liquid storage portion includes a first capillary material provided near the opening of the housing, and a second capillary material in contact with the first capillary material and spaced from the opening by the first capillary material. The second portion of the liquid storage portion is substantially empty and may be suitable for holding a liquid aerosol-forming substrate.

[0047] The cartridge preferably further includes a fluid permeable heater assembly extending across the opening of the housing.

[0048] In an embodiment of the present invention, the first portion of the liquid storage portion occupies less than 50% of the volume of the liquid storage portion, preferably 10% to 30%, more preferably 15% to 25%, and most preferably about 20%.

[0049] The capillary material extends across the entire cross-section of the first portion of the liquid storage portion so that the liquid aerosol generating substrate cannot flow directly to the heater assembly or the opening of the cartridge.

[0050] According to a further aspect of the present invention, there is provided an aerosol generating system comprising a cartridge according to the present invention.

[0051] The system may further comprise a heater assembly and an electrical circuit connected to a power source, the electrical circuit being configured to monitor the electrical resistance of the heater assembly or one or more filaments of the heater assembly and to control the power supply to the heater assembly depending on the electrical resistance of the heater assembly or the one or more filaments.

[0052] The electrical circuit may comprise a microprocessor, which may be a programmable microprocessor. The electrical circuit may comprise further electronic components. The electrical circuit may be configured to regulate the power supply to the heater assembly. The power may be supplied continuously to the heater assembly after activation of the system or intermittently, such as for each inhalation. The power may be supplied to the heater assembly in the form of current pulses.

[0053] Advantageously, the system comprises a power source within the body of the housing. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may need to be recharged and may have a capacity that allows 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 about 6 minutes, corresponding to the typical time taken to smoke one conventional cigarette, or a multiple of 6 minutes. In another example, the power source may have a capacity sufficient to allow a predetermined number of puffs or discontinuous activation of the heater assembly.

[0054] The aerosol generating system preferably includes a housing. The housing is preferably elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics or composite materials containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications such as, for example, polypropylene, polyetheretherketone (PEEK) and polyethylene. The material is preferably lightweight and not brittle.

[0055] The aerosol generating system is preferably portable. The aerosol generating system can have a size comparable to that of a conventional cigarette or roll-up tobacco. The overall length of the smoking system can be from approximately 30 mm to approximately 150 mm. The outer diameter of the smoking system can be from approximately 5 mm to approximately 30 mm.

[0056] An aerosol-forming substrate is a substrate having the ability to release volatile compounds capable of forming an aerosol. The volatile compounds can be released by heating the aerosol-forming substrate.

[0057] The aerosol-forming substrate can include plant-derived materials. The aerosol-forming substrate can include tobacco. The aerosol-forming substrate can include a tobacco-containing material that includes volatile tobacco flavor compounds released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate can include a non-tobacco-containing material. The aerosol-forming substrate can include homogenized plant-derived materials. The aerosol-forming substrate can include homogenized tobacco materials. The aerosol-forming substrate may include at least one aerosol-forming agent. The aerosol-forming substrate can include other additives and components (such as flavorants).

[0058] The system preferably includes a mouthpiece, where the cartridge is inserted into the system in a direction such that the opening of the cartridge faces away from the mouthpiece.

[0059] In another preferred embodiment, the cartridge is inserted into the system in a direction such that the opening of the cartridge faces the mouthpiece. Depending on the usage situation, one of these cartridge orientations may provide better performance compared to the other.

[0060] According to a further aspect of the invention, there is provided a cartridge for use in an aerosol generating system comprising a liquid storage portion including a housing for holding a liquid aerosol-forming substrate, the liquid storage portion including a heater assembly, and a capillary material provided in contact with the heater assembly, wherein the average porosity or pore size of the region of the capillary material adjacent to the heater assembly is smaller than the average porosity or pore size of the region of the capillary material remote from the heater assembly. The portion of the capillary material in this region can be compressed to reduce its porosity or pore size. The liquid storage portion may include at least two portions in fluid communication with each other, a first portion of the liquid storage portion including the capillary material, and a second portion of the liquid storage portion including a container for holding the liquid aerosol-forming substrate and supplying the liquid to the region of the capillary material having a larger porosity or pore size.

[0061] The invention also relates to a method of manufacturing a cartridge for use in an electrically operated aerosol generating system, the method including the steps of providing a liquid storage portion including a housing having a first part and a second part, providing a heater assembly, arranging a first capillary material within the first part of the housing of the liquid storage portion such that the first capillary material is provided in direct contact with the heater assembly, and arranging a second capillary material within the first part of the housing of the liquid storage portion such that the second capillary material is in contact with the first capillary material and is spaced from the heater assembly by the first capillary material. The second part of the liquid storage portion is substantially empty and is suitable for holding the liquid aerosol-forming substrate.

[0062] Preferably, the first capillary material is compressed upon or prior to insertion into the housing such that its pore size or porosity is reduced as compared to the pore size or porosity in the relaxed state.

[0063] One aspect of the present invention further provides a method of manufacturing a cartridge for use in an aerosol generating system, the method comprising the steps of providing a liquid storage portion including a housing, providing a heater assembly, and disposing a capillary material within the housing of the liquid storage portion such that the capillary material is provided in direct contact with the heater assembly, wherein the method includes the step of compressing a portion of the capillary material upon or prior to placement of the housing such that the porosity or pore size of the portion of the capillary material is reduced.

[0064] The present invention also provides an aerosol generating system as described herein as an electrically operated smoking system.

[0065] The term "substantially planar" filament arrangement is preferably used to mean a filament arrangement in the form of a substantially two-dimensional topological manifold. Thus, a substantially planar filament arrangement extends two-dimensionally along a surface that is substantially larger than a third dimension. In particular, the two-dimensional dimensions of the substantially planar filament arrangement within that surface are at least five times larger than the third dimension perpendicular to the surface. An example of a substantially planar filament arrangement is a structure between two substantially parallel surfaces, where the distance between these two surfaces is substantially smaller than the extension within that surface. In some embodiments, the substantially planar filament arrangement is planar. In other embodiments, the substantially planar filament arrangement is bent along one or more dimensions, for example, forming a dome shape or a bridge shape.

[0066] The term "filament" is preferably used to mean an electrical path disposed between two electrical contacts. The filament may optionally be branched or divided into several paths or filaments respectively, or may merge from several electrical paths into one path. The filament may have a round, square, flat or any other cross-sectional form. The filament may be arranged linearly or curvilinearly.

[0067] The term "filament arrangement" is preferably used to mean the arrangement of one or preferably a plurality of filaments. The filament arrangement may be, for example, a series of filaments arranged in parallel with each other. It is preferable that the filaments form a mesh. The mesh may be a woven or non-woven fabric.

[0068] It is understood that, where appropriate, the features of one aspect of the present invention may be provided in any suitable combination in relation to another aspect of the present invention.

[0069] The present invention will be further described by way of illustration only with reference to the following accompanying drawings.

Brief Description of the Drawings

[0070]

Figure 1a

Figure 1b

Figure 1c

Figure 1d

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

DETAILED DESCRIPTION OF THE INVENTION

[0071] Figures 1a - 1d are schematic views of an aerosol generating system including a cartridge according to an embodiment of the present invention. Figure 1a is a schematic view of an aerosol generating device 10 and a separate cartridge 20, which together form an aerosol generating system. In this example, the aerosol generating system is an electrically operated smoking system.

[0072] The cartridge 20 includes an aerosol - forming substrate and is configured to be received within a recess 18 in the device. The cartridge 20 should be replaceable by the user when the aerosol - forming substrate provided within the cartridge is depleted. Figure 1a shows the cartridge 20 immediately before insertion into the device, and the arrow 1 in Figure 1a indicates the insertion direction of the cartridge.

[0073] The aerosol generating device 10 is portable and has a size comparable to that of a conventional cigar or cigarette. The device 10 includes a main body 11 and a mouthpiece portion 12. The main body 11 includes a battery 14 (such as a lithium iron phosphate battery), a control electronic circuit 16, and a recess 18. The mouthpiece portion 12 is connected to the main body 11 by a hinged connection 21 and is movable between an open position shown in FIGS. 1a - 1c and a closed position shown in FIG. 1d. The mouthpiece portion 12 is placed in the open position to allow insertion and removal of the cartridge 20 and, as will be described below, is placed in the closed position when the system is used for aerosol generation. The mouthpiece portion includes a plurality of air inlets 13 and an outlet 15. In use, the user sucks or inhales at the outlet, drawing air from the air inlets 13 through the mouthpiece portion to the outlet 15 and then into the user's mouth or lungs. An internal baffle 17 is provided to force the flow of air passing through the cartridge through the mouthpiece portion 12, as will be described below.

[0074] The recess 18 has a circular cross - section and is sized to receive the housing 24 of the cartridge 20. An electrical connector 19 is provided on the side of the recess 18 to provide an electrical connection between the control electronic circuit 16 and the battery 14 and corresponding electrical contacts on the cartridge 20.

[0075] FIG. 1b shows the system of FIG. 1a with the cartridge inserted into the recess 118 and the cover 26 removed. In this position, the electrical connector is supported against the electrical contacts on the cartridge, as will be described below.

[0076] FIG. 1c shows the system of FIG. 1b with the cover 26 completely removed and the mouthpiece portion 12 moved to the closed position.

[0077] Figure 1d shows the system of Figure 1c with the mouthpiece portion 12 in the closed position. The mouthpiece portion 12 is held in the closed position by a fastener mechanism. The mouthpiece portion 12 in the closed position holds the cartridge in electrical contact with the electrical connector 19 so that good electrical connection is maintained during use regardless of the orientation of the system. The mouthpiece portion 12 may include an annular elastic element that engages the surface of the cartridge and is compressed between the rigid mouthpiece housing element and the cartridge when the mouthpiece portion 12 is in the closed position. This maintains good electrical connection regardless of manufacturing tolerances.

[0078] Of course, other mechanisms for maintaining good electrical connection between the cartridge and the device may also be employed, either as an alternative or in addition. For example, the housing 24 of the cartridge 20 may be provided with grooves or threads (not shown) that engage corresponding threads or grooves (not shown) formed in the wall of the recess 18. Threaded engagement between the cartridge and the device can be used to ensure correct rotational alignment, as well as to hold the cartridge within the recess and provide good electrical connection. The threaded connection may extend for less than half a rotation or several rotations of the cartridge. Alternatively, or in addition, the electrical connector 19 may be biased to contact the contacts on the cartridge.

[0079] Those skilled in the art will be able to conceive of other cartridge designs incorporating the capillary material arrangement according to the present disclosure. For example, the cartridge may include a mouthpiece portion, may include multiple heater assemblies, and may have any desired shape. Moreover, the capillary assembly according to the present disclosure can be used in other types of systems already described, including humidifiers, air fresheners, and other aerosol generating systems.

[0080] The above exemplary embodiments illustrate but do not limit. In light of the exemplary embodiments discussed above, other embodiments consistent with the above exemplary embodiments will now be apparent to those skilled in the art.

[0081] The cartridge shown in FIG. 2 includes a polypropylene housing 24 having a liquid storage portion consisting of two parts. The first component 32 of the liquid storage portion includes a first capillary material 36 and a second capillary material 38. The second component 34 of the liquid storage portion is an empty tank that can be filled or partially filled with a liquid aerosol generating substrate.

[0082] A ceramic substrate 42 is provided at the upper end of the cartridge. The substrate 24 defines an opening 44 and has electrical contacts (not shown) on the opposite side. The heater element 46 is connected to the electrical contacts of the substrate 32 and extends over the opening 44 defined by the substrate.

[0083] Both the first capillary material 36 and the second capillary material 38 hold the liquid aerosol forming substrate. The first capillary material 16 in direct contact with the heater element 46 has a higher thermal decomposition temperature (at least 160 °C or more, for example, about 250 °C, etc.) than the second capillary material 38. The first capillary material 36 effectively serves as a spacer that separates the heater element 46 from the second capillary material 38 so that the second capillary material 38 is not exposed to a temperature above its thermal decomposition temperature. The thermal gradient across the entire first capillary material 36 is such that the second capillary material 38 is exposed to a temperature below its thermal decomposition temperature. The second capillary material 38 can be selected to have better wicking performance than the first capillary material 36, can hold more liquid per unit volume than the first capillary material 36, and can be less expensive than the first capillary material 36. In this example, the first capillary material 36 is a heat-resistant element such as a glass fiber or an element containing glass fibers, and the second capillary material 38 is a polymer such as high-density polyethylene (HDPE) or polyethylene terephthalate (PET).

[0084] Figure 3 is an exploded view of a cartridge similar to the cartridge of Figure 2. The cartridge includes a generally circular cylindrical housing 24 that includes a first part 32 and a second part 34. The first part of the housing 24 includes first and second capillary materials 36, 38 that are immersed in a liquid aerosol forming substrate. In this example, the aerosol forming substrate includes 39 weight percent glycerin, 39 weight percent propylene glycol, 20 weight percent water and flavorant, and 2 weight percent nicotine. The capillary material here is a material that actively transports liquid from one end to the other and can be manufactured from any suitable material. In this example, the capillary material is formed from polyester.

[0085] The housing 24 has an open end to which the heater assembly is fixed. The heater assembly includes a substrate 42 having an opening 44 formed therein, a pair of electrical contacts 48 fixed to the substrate 42 and separated from each other by a gap 40, and a resistive heater element 46 extending over the opening 44 and fixed to the electrical contacts 48 on the opposite side of the opening 44.

[0086] The heater assembly is covered by a removable cover 26. The cover 26 includes a liquid impermeable plastic sheet that is adhered to the heater assembly but can be easily peeled off. Tabs are provided on the sides of the cover so that the user can grasp the cover when peeling it off. Adhesion is described as a way to fix the impermeable plastic sheet to the heater assembly, but it will be apparent to those skilled in the art that other methods familiar to those skilled in the art, including heat sealing and ultrasonic welding, can also be used as long as the cover can be easily removed by the consumer.

[0087] FIG. 4 shows an embodiment in which the housing 24 has the shape of a right circular cylinder with a circular cross-section. The first and second capillary materials are made of the same material and are integrally molded as a single continuous piece of capillary material 60 having the shape of a frustum of a cone. The diameter of the truncated tip of the cone corresponds to the inner diameter of the cylindrical housing. The diameter of the base of the cone is twice the size of the inner diameter of the cylindrical housing. The capillary material 60 is inserted into the cylindrical housing 24 with the tip first until the surface of the base of the cone is flush with the front surface of the cylindrical housing. After insertion, the capillary material 40 is compressed, and due to the relative shapes of the capillary material and the cylindrical housing, the compression of the capillary material 60 increases towards the end face of the cylindrical housing. At the same time, the pore size or porosity of the capillary material near the end face of the housing decreases such that it is smaller than the pore size or porosity of the capillary material located at the center of the cylindrical housing. The open end of the cylindrical housing on the right side of FIG. 4 is provided in a closed state such that the inside of the cylindrical housing forms a tank storage portion for holding the liquid aerosol generating substrate. The heater assembly shown in FIGS. 2 and 3 can be provided at the other end.

[0088] Figure 5 shows an alternative embodiment having a similar effect to the embodiment illustrated in Figure 4. In this case, on the inner surface of the housing, a conical shape is provided such that the inner taper faces one end of the housing 24. Here, the inner diameter of the housing 24 on the left side in Figure 5 is half of the inner diameter of the housing 24 on the right side. Again, the first and second capillary materials are manufactured from the same material and are integrally molded as a single continuous piece of capillary material 60. The piece of capillary material 60 has a regular cylindrical shape with a circular cross-section. The diameter of the cylindrical piece of capillary material 60 corresponds to the inner diameter of the housing 24 on the right side in Figure 5. The capillary material 60 is inserted into the housing 24 until the end face of the capillary material 60 is flush with the front face of the cylindrical housing having the smaller diameter, i.e., the end face on the left side of the housing 24. Again, after insertion, the capillary material 60 is compressed, and due to the relative shape of the capillary material and the cylindrical housing, the compression of the capillary material 60 increases towards the end face on the left side of the cylindrical housing 24. At the same time, the pore size or porosity of the capillary material 60 near the end face of the housing decreases such that it is smaller than the pore size or porosity of the capillary material 60 located at the center of the cylindrical housing. Again, the open end of the cylindrical housing on the right side in Figure 5 is provided in a closed state such that the inside of the cylindrical housing forms a tank storage portion for holding the liquid aerosol generating substrate. The other end face of the housing can be provided with the heater assembly illustrated in Figures 2 and 3.

[0089] Figure 6 shows a further embodiment, which shows only the capillary material 50 for use in combination with a cylindrical housing. Again, the first and second capillary materials are formed from a single continuous piece of the same material 50. The capillary material is a web of rectangular pieces of capillary material having a thickness of about 25% of the inner diameter of the cylindrical housing of the cartridge. The width of the web of capillary material corresponds to the outer circumference of the housing. The length of the web of capillary material is about half the length of the housing of the cartridge. The web of capillary material is wound to form a cylindrical shape. An air channel 52 is formed in the center of the wound capillary material. A tubular fluid-permeable heater element 54 is provided in the air channel 52 such that the heater is in direct contact with the inner surface 56 of the wound capillary material 50. When the capillary material is wound, the portion 50a of the material closer to the central axis of the cylinder is compressed more than the material of the portion 50b located radially outward of the capillary material. Thus, again a gradient of pore size or porosity is obtained, where the pore size or porosity of the capillary material 50 continuously decreases in the direction of the heater element 54 within the capillary material. The capillary material is in fluid communication with a liquid reservoir (not shown), where the liquid reservoir is provided within the portion of the housing not occupied by the capillary material. A partition is provided within the housing so that the liquid matrix is not in direct communication with the air flow channel 52.

[0090] It is understood that different methods and configurations are possible to obtain capillary materials with different pore sizes or porosities in different regions. In each example, the region of smaller pore size or porosity is located at one end of the capillary material. Thus, the region of smaller pore size or porosity is located at the heater. Thus, the gradient of pore size or porosity improves the capillary action in the material to draw the aerosol-generating matrix liquid to the heater.

[0091] 1. A cartridge for use in an aerosol-generating system, A liquid storage portion, A housing for holding a liquid aerosol forming substrate, the liquid storage portion having at least two portions in fluid communication with each other, the first portion of the liquid storage portion being - a heater assembly; - a first capillary material provided in contact with the heater assembly; - a second capillary material in contact with the first capillary material and having a gap with the heater assembly through the first capillary material; The second portion of the liquid storage portion includes a container for holding a liquid aerosol forming substrate, and supplies the liquid to the second capillary material, a cartridge. 2. The cartridge according to 1, wherein the liquid storage portion includes an opening, and the heater assembly extends across the opening of the housing. 3. A cartridge for use in an aerosol generating system, a liquid storage portion, a housing for holding a liquid aerosol forming substrate, the housing including one having an opening, the liquid storage portion includes at least two portions in fluid communication with each other, the first portion of the liquid storage portion being - a first capillary material provided near the opening of the housing; - a second capillary material in fluid contact with the first capillary material and having a gap with the opening through the first capillary material; The second portion of the liquid storage portion includes a container for holding a liquid aerosol forming substrate, and supplies the liquid to the second capillary material, a cartridge. 4. The cartridge according to 3, further comprising a fluid-permeable heater assembly extending across the opening of the housing. 5. The cartridge according to any one of 1 to 4, wherein the average pore size or porosity of the first capillary material is smaller than the average pore size or porosity of the second capillary material. 6. The cartridge according to any one of 1 to 5, wherein the first capillary material has a fiber size or pore size of 0.1 to 50 μm, preferably 0.5 to 10 μm, and most preferably about 4 μm. 7. The cartridge according to any one of 1 to 6, wherein the first capillary material has a density of less than 2 g / ml, preferably about 0.5 g / ml. 8. The cartridge according to any one of 1 to 7, wherein the second capillary material has a fiber size or pore size of 1 to 100 μm, preferably 15 to 40 μm, and most preferably about 25 μm. 9. The cartridge according to 7 or 8, wherein the second capillary material has a density of less than 1 g / ml, preferably 0.1 to 0.3 g / ml. 10. The cartridge according to any one of 1 to 9, wherein the first capillary material or the second capillary material is compressed within the housing such that its effective pore size is reduced. 11. The cartridge according to any one of 1 to 10, wherein the first capillary material and the second capillary material comprise different regions of the same capillary material element. 12. The cartridge according to any one of 1 to 11, wherein the compression of the capillary material when disposed within the housing is such that the pore size or porosity of the capillary material decreases continuously towards the heater assembly. 13. The cartridge according to any one of 1 to 12, wherein the first and second capillary materials are formed as an integral element from a continuous piece of material, whereby the cross-section increases at one end of the element. 14. The cartridge according to any one of 1 to 13, wherein the inner surface of the housing has the shape of a right circular cylinder with a circular cross-section, and the piece of capillary material is conical. 15. The cartridge according to any one of 1 to 14, wherein the capillary material has the shape of a regular cylinder with a circular cross-section, and the inner surface of the housing includes a tapered portion at the open end, and the capillary material is compressed by this tapered portion after being inserted into the housing. 16. A cartridge for use in an aerosol generating system, comprising: a liquid storage portion, including a housing for holding a liquid aerosol forming substrate, said liquid storage portion comprising: - a heater assembly, - a capillary material provided in contact with said heater assembly, wherein an average porosity or pore size of a region of said capillary material adjacent to said heater assembly is smaller than an average porosity or pore size of a region of said capillary material remote from said heater assembly; a cartridge. 17. The cartridge according to claim 16, wherein a portion of said capillary material in said region is compressed to reduce its porosity or pore size. 18. The liquid storage portion includes at least two portions in fluid communication with each other, wherein a first portion of said liquid storage portion includes said capillary material, a second portion of said liquid storage portion includes a container for holding a liquid aerosol forming substrate, and said liquid is supplied to a region of said capillary material having a larger porosity or pore size; the cartridge according to claim 16 or 17. 19. A method of manufacturing a cartridge for use in an aerosol generating system, comprising: - providing a liquid storage portion including a housing having a first portion and a second portion; - providing a heater assembly; - disposing a first capillary material within said first portion of said housing of said liquid storage portion such that said first capillary material is in direct contact with said heater assembly; - disposing a second capillary material within said first portion of said housing of said liquid storage portion such that said second capillary material is in contact with said first capillary material and is spaced from said heater assembly by said first capillary material; wherein said second portion of said liquid storage portion is substantially empty and suitable for holding a liquid aerosol forming substrate; a method. 20. The method according to any one of 1 to 19, wherein a part of the capillary material is compressed during or before insertion into the housing so that the porosity or the pore size of the part of the capillary material decreases. 21. A method for manufacturing a cartridge for use in an aerosol generating system, comprising: - providing a liquid storage part including a housing; - providing a heater assembly; - disposing a capillary material within the housing of the liquid storage part such that the capillary material is in direct contact with the heater assembly. The method includes a step of compressing a part of the capillary material during or before the placement of the housing so that the porosity or the pore size of the part of the capillary material decreases. 22. An aerosol generating system comprising the cartridge according to any one of 1 to 17. 23. The aerosol generating system according to 22, further comprising a mouthpiece, wherein the cartridge is inserted into the system in a direction away from or towards the mouthpiece with the opening of the cartridge. 24. The aerosol generating system according to 22 or 23, wherein the system is an electrically operated smoking system.

Claims

1. A cartridge for use in an aerosol generating system, comprising: - a housing in which an air flow channel is provided; - a liquid reservoir for holding a liquid aerosol-forming substrate; - a heater assembly disposed within the air flow channel; - a capillary material provided in contact with the heater assembly; wherein the capillary material is wound to form a cylindrical shape; the capillary material includes a first capillary material having a first pore size and a second capillary material having a second pore size, the first capillary material having a higher thermal decomposition temperature than the second capillary material, and the porosity of the first capillary material being smaller than the porosity of the second capillary material; a cartridge.

2. The cartridge according to claim 1, wherein the capillary material is a web of rectangular strips of the capillary material.

3. The cartridge according to claim 2, wherein the web of the capillary material has a thickness that is about 25% of the inner diameter of the housing.

4. The cartridge according to claim 2 or 3, wherein the length of the web of the capillary material is about half the length of the housing of the cartridge.

5. The cartridge according to any one of claims 2 to 4, wherein the web of the capillary material has a length that is smaller than the length of the housing of the cartridge.

6. The cartridge according to any one of claims 1 to 5, wherein the pore size or porosity of the capillary material continuously decreases in the direction of the heater assembly within the capillary material.

7. The cartridge according to any one of claims 1 to 6, wherein the heater assembly is a tubular fluid-permeable heater element.

8. The cartridge according to any one of claims 1 to 7, wherein the housing is cylindrical.

9. The cartridge according to any one of claims 1 to 8, wherein the capillary material is in fluid communication with the liquid reservoir.

10. The cartridge according to any one of claims 1 to 9, wherein the capillary material closer to the heater assembly has a density of less than 1 g / ml.

11. The cartridge according to any one of claims 1 to 10, wherein the capillary material closer to the heater assembly has a fiber size or pore size of 0.5 to 10 μm.

12. The cartridge according to any one of claims 1 to 11, wherein the capillary material in the portion located radially outside the capillary material has a density of less than 2 g / ml.

13. The cartridge according to any one of claims 1 to 12, wherein the capillary material in the portion located radially outside the capillary material has a fiber size or pore size of 15 to 40 μm.

14. The cartridge according to any one of claims 1 to 13, wherein the capillary material in the portion located radially outside the capillary material has a density of less than 1 g / ml.

15. The cartridge according to any one of claims 1 to 14, wherein a partition is provided in the housing so that the liquid aerosol-forming substrate does not communicate directly with the air flow channel.

16. A method of manufacturing a cartridge for use in an aerosol generating system, comprising: - providing a housing in which an air flow channel is provided; - providing a liquid reservoir for holding a liquid aerosol-forming substrate; - disposing a heater assembly in the air flow channel; - disposing a capillary material in contact with the heater assembly, wherein the capillary material is wound to form a cylindrical shape, the capillary material includes a first capillary material having a first pore size and a second capillary material having a second pore size, the first capillary material has a higher thermal decomposition temperature than the second capillary material, and the porosity of the first capillary material is smaller than the porosity of the second capillary material. Method.

17. An aerosol generating system comprising the cartridge according to any one of claims 1 to 15.

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