Aerosol Generator and Heater Assembly

Abstract

An aerosol generating device (500) for coupling to a cartridge, the aerosol generating device (500) comprising a cartridge coupling portion for engaging a cartridge containing an aerosol-forming substrate. The aerosol generating device (500) further comprises an airflow passage defined between an air inlet (510) and an air outlet (520), and a heater assembly. The heater assembly comprises a fluid-permeable heating element (540) configured to heat the aerosol-forming substrate from the cartridge. The heater assembly comprises a first side and a second side, the first side facing opposite the second side, the first side forming at least a portion of a surface of a wall of the airflow passage, and the second side forming a portion of the cartridge coupling portion and configured to contact the cartridge and receive the aerosol-forming substrate.

Description

[Technical field]

[0001] The present disclosure relates to an aerosol generating device for connection to a cartridge, a heater assembly for an aerosol generating device, a cartridge, and an aerosol generating system. [Background technology]

[0002] Aerosol generating systems configured to generate an inhalable aerosol from an aerosol-forming substrate are known in the art. Many prior aerosol generating systems comprise an aerosol generating device that can be coupled to a cartridge. A typical cartridge for use in an aerosol generating device comprises an aerosol-forming substrate and a heater assembly, where the heater assembly comprises a heating element. The cartridge may further comprise a wicking material adjacent to or in contact with the aerosol-forming substrate and the heating element. The wicking material is configured to transport the aerosol-forming substrate to the heating element. In use, the heating element is configured to vaporize the aerosol-forming substrate. An airflow is provided past the heating element to entrain the generated vapor. The vapor condenses in the airflow and an aerosol is formed. The aerosol may then be inhaled by a user. The cartridge may be removably connectable to the aerosol generating device. The aerosol generating device typically comprises a power source configured to provide power to the heating element via an electrical connector.

[0003] In this type of aerosol generating system, it is desirable to minimize the amount of power required to heat the aerosol-forming substrate. This is particularly desirable in portable aerosol generating systems where the system includes a portable power source, such as a battery. To minimize power usage and efficiently heat the aerosol-forming substrate, the heating element may be in direct contact with the wicking material and, therefore, the aerosol-forming substrate.

[0004] Repeated use of the aerosol generating system over numerous heating cycles requires repeated heating of the wicking material. This may lead to degradation of the wicking material over time. Degradation may occur due to heating of the wicking material. Degradation may also occur due to chemical interactions between the aerosol-forming substrate and the wicking material, mechanical stress on the wicking material, and particle accumulation on the surface of the wicking element. Degradation of the wicking material may lead to undesirable effects such as less efficient heat transfer between the heating element and the wicking material, less efficient transfer of the aerosol-forming substrate from the wicking material to the heating element, or generation of aerosols containing undesirable components. In addition, hot spots may develop within the heating element during use of the aerosol generating system. Hot spots are areas of the heating element that have a temperature higher than the average temperature of the heating element during operation. These hot spots may lead to degradation of the wicking material.

[0005] As a result of degradation, the wicking material limits the lifespan of any cartridge.

[0006] It would be desirable to provide an aerosol generating system, and an aerosol generating device for such a system, that requires less frequent disposal of the heater assembly. Summary of the Invention

[0007] According to a first aspect of the present disclosure, there is provided an aerosol generating device for coupling to a cartridge. The aerosol generating device may comprise a cartridge coupling portion for engaging a cartridge containing an aerosol-forming substrate. The aerosol generating device may comprise an airflow passage defined between an air inlet and an air outlet. The aerosol generating device may further comprise a heater assembly, the heater assembly comprising a fluid-permeable heating element configured to heat the aerosol-forming substrate from the cartridge, the heater assembly comprising a first side and a second side, the first side facing opposite the second side, the first side forming at least a part of a surface of a wall of the airflow passage, and the second side forming a part of the cartridge coupling portion and configured to contact the cartridge and receive the aerosol-forming substrate.

[0008] The heater assembly may be disposed within the device and coupled to the cartridge. The aerosol generating device may be reusable. The cartridge may be disposable. Advantageously, if the cartridge needs to be discarded, it may be disconnected from the device, discarded, and replaced. The heater assembly may be retained within the device instead of being removed and discarded. Thus, the heater assembly may be reused. The heater assembly may be more expensive to manufacture compared to the cartridge elements, so it is advantageous to prevent unnecessary disposal of the heater assembly.

[0009] The air inlet may be defined in a side wall of the device. The air outlet may be defined in an end wall of the device. The side wall of the device may extend perpendicular to the end wall of the device. The configuration of the air inlet and air outlet may allow air to flow past the heater assembly and thus entrain the vaporized aerosol-forming substrate. The air outlet may be configured to align with an opening in the cartridge. The entrained vaporized aerosol-forming substrate may aerosolize in the airflow and may pass through the air outlet into the cartridge.

[0010] The second side of the heater assembly may be located outside the airflow passage. The second side of the heater assembly may be configured such that at least a portion of the second side contacts the wicking material of the cartridge.

[0011] The heating assembly may be a planar heater assembly. The heating element may be a planar heating element. The heating element may be perpendicular to the longitudinal axis of the device.

[0012] The heating element may comprise at least one filament. The heating element may comprise a plurality of electrically conductive filaments. As used herein, the term "filament" refers to an electrical path disposed between two electrical contacts. The at least one filament may have a round cross-section, a square cross-section, a flat cross-section, or a cross-section of any other form. The heating element may, for example, be an array of filaments disposed parallel to one another. Preferably, the filaments may form a mesh.

[0013] The heating element may be a mesh heating element. The heating element may comprise a mesh. The heating element may allow vapor to flow from the second side of the heater assembly to the first side of the heater assembly. The heating element may not allow liquid to flow from the second side of the heating element to the first side of the heating element.

[0014] The conductive filaments may define gaps between the filaments, and the gaps may have a width of 10 micrometers to 100 micrometers. Preferably, the filaments create capillary action in the gaps, increasing the contact area between the heating element and the aerosol-forming substrate, such that liquid to be vaporized in use is drawn into the gaps.

[0015] The conductive filaments may form a mesh with a size of 60 to 240 filaments per centimeter (±10 percent). Preferably, the mesh density is 100 to 140 filaments per centimeter (±10 percent). More preferably, the mesh density is approximately 115 filaments per centimeter. The gap width may be 100 micrometers to 25 micrometers, preferably 80 micrometers to 70 micrometers, and more preferably approximately 74 micrometers. The percentage of the open area of ​​the mesh, which is the ratio of the area of ​​the gaps to the total area of ​​the mesh, may be 40 percent to 90 percent, preferably 85 percent to 80 percent, and more preferably approximately 82 percent. The conductive filaments may have a diameter of 8 micrometers to 100 micrometers, preferably 10 micrometers to 50 micrometers, more preferably 12 micrometers to 25 micrometers, and most preferably approximately 16 micrometers.

[0016] The area of ​​the conductive filament mesh may be small, for example, 50 square millimeters or less, preferably 25 square millimeters or less, and more preferably approximately 15 square millimeters. The size is chosen to allow for the integration of the heating element into a handheld system. Sizing the conductive filament mesh, array, or fabric to 50 square millimeters or less reduces the amount of total power required to heat the conductive filament mesh while still ensuring that the conductive filament mesh is in sufficient contact with the aerosol-forming substrate. The conductive filament mesh may be, for example, rectangular and may have a length of 2 millimeters to 10 millimeters and a width of 2 millimeters to 10 millimeters. Preferably, the mesh has dimensions of approximately 5 millimeters by 3 millimeters.

[0017] The heating element may comprise a porous material. Advantageously, a mesh heating element, a heating element comprising a mesh, or a heating element comprising a porous material may provide a large surface area in contact with the liquid aerosol-forming substrate. This large surface area may provide efficient evaporation of the liquid aerosol-forming substrate.

[0018] Preferably, the heating element comprises a single filament. A heating element comprising a single filament may also be called a heating wire. The single filament may have a diameter of 0.1 mm to 0.5 mm. The single filament may have a diameter of 0.02 mm to 0.2 mm.

[0019] The heating element, or portions thereof, may include an electrically resistive material. The heating element may be configured to be resistively heated. In other words, the heating element may be configured to generate heat when an electric current is passed through the heating element. The heating element, or portions thereof, may include or be formed of any material having suitable electrical and mechanical properties, for example, a suitable electrically resistive material. Suitable materials may include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable alloys include constantan, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel, iron, and cobalt-based superalloys, Timetal®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation, 1999 Broadway Suite 4300, Denver Colorado. In composite materials, the electrically resistive material may be embedded in, encapsulated in, or coated with an insulating material, or vice versa, depending on the required energy transfer kinetics and external physicochemical properties. The heating element, or a portion thereof, may comprise an etched foil of metal insulated between two layers of inert material. In that case, the inactive material may include Kapton®, a full layer polyimide, or a mica foil.Kapton® is a registered trademark of EI du Pont de Nemours and Company, 1007 Market Street, Wilmington, Delaware 19898, United States of America.

[0020] Preferably, the heating element comprises stainless steel, which may provide the heating element with desirable mechanical properties, corrosion resistance, and high electrical resistance.

[0021] The heating element may include a ferrimagnetic material. The heating element may include a ferromagnetic material. The heating element may be formed of a ferrimagnetic or ferromagnetic material. At least a portion of the heating element may be formed of a ferrimagnetic or ferromagnetic material. The electrical resistance of the heating element may increase as the frequency of the alternating current applied to the heating element increases. The use of a heating element including a ferrimagnetic or ferromagnetic material may advantageously generate more heat locally without having to increase the electrical resistance of the heating element and thus reduce the diameter of the heating element. Reducing the diameter may compromise the mechanical strength of the heating element.

[0022] The electrical resistance of the heating element may be between 0.1 ohms and 5 ohms. Preferably, the electrical resistance of the heating element may be between 0.4 ohms and 2 ohms.

[0023] The heating element may be coated with a corrosion resistant material, which may increase the lifespan of the heating element. The heating element may be coated with a ceramic material.

[0024] The heater assembly may be configured to contact the wicking portion of the cartridge. The heating element may be configured to contact the wicking portion of the cartridge.

[0025] The heater assembly may comprise a support element. The support element may provide mechanical support to the heating element. The support element may laterally support the heating element. The support element may comprise a thermally conductive material in thermal contact with the heating element. The support element may be configured to absorb heat generated by the heating element. Advantageously, the presence of a support element comprising a thermally conductive material may reduce the temperature of the heating element in areas where the heating element is not in contact with the wicking material or the aerosol-forming substrate. This may reduce overheating of the heating element and preferably extend the life of the heating element. Additionally, this may reduce or slow down the degradation of the wicking material in contact with the heating element.

[0026] The support element may comprise at least one of aluminum, copper, brass, gold, silver, or a thermally conductive ceramic. Advantageously, these materials have high thermal conductivity.

[0027] The thermal conductivity of the support element may be at least 10 W / mK. The thermal conductivity of the support element may be at least 50 W / mK. The thermal conductivity of the support element may be at least 200 W / mK.

[0028] The support element may comprise at least one support pin. The support element may comprise at least 4, at least 6, at least 8, at least 10, or at least 12 support pins. A heating element may engage at least one support pin. The heating element may be wound or shaped to be wound around at least one support pin. The heating element may be a heating wire, the heating wire passing around each of the support pins.

[0029] The at least one support pin may be cylindrical. The at least one support pin may have a cross-section having a diameter of 0.5 mm to 5 mm, preferably 1 mm to 2 mm.

[0030] The heater assembly may further comprise a heater holder. The heater holder may provide mechanical support to the support element. The heater holder may comprise an upper plate and a lower plate. The heating element may be disposed between the upper and lower plates. Advantageously, a heater holder comprising upper and lower plates with a heating element disposed therebetween may be simple and straightforward to manufacture.

[0031] The heater holder may have an opening defined therethrough. The opening may be defined through the upper plate and the lower plate. The heating element may span at least a portion of the opening. The opening may be configured to allow the aerosol-forming substrate to flow between the second side of the heater assembly and the first side of the heater assembly. The opening may be configured to allow gases, such as air and vapor generated from the aerosol-forming substrate, to flow between the second side of the heater assembly and the first side of the heater assembly.

[0032] The aerosol generating device may further comprise a first electrical connector and a second electrical connector. The first electrical connector and the second electrical connector may be configured to provide electrical power to the heating element. The electrical connector may be placed in electrical contact with the heating element. The first electrical connector may comprise a first contact pad and the second electrical connector may comprise a second electrical contact pad, the first electrical contact pad and the second electrical contact pad configured to be in electrical contact with the heating element. The electrical connector may extend outside the heater assembly to enable provision of electrical energy from a power source to the electrical connector and thus to the heating element. In operation, the heating element may be heated as a result of an electrical current passing through the heating element. The first electrical connector and the second electrical connector may be positioned on opposite sides of the heating element. An electrical current passing from the first electrical connector to the second electrical connector may pass through the heating element.

[0033] The support element may be placed adjacent to the opening. The support element may be placed as close as possible to the opening. The distance between the support element and the opening may be less than 2 mm, preferably less than 1 mm. Advantageously, this may minimize the overall length of the heating element. The length of the heating element that does not span the opening may also be reduced. The percentage of the heating element that spans the opening may be increased. Increasing the percentage of the heating element that spans the opening may increase the percentage of the second side of the heating element that is configured to contact the cartridge and receive the aerosol-forming substrate. Advantageously, less material may be required to manufacture the heating element while not reducing the performance of the heating element. The electrical connector may be in electrical contact with the heating element at a distance further from the opening than the support element from the opening. The first electrical connector may be in electrical contact with a first end of the heating element. The second electrical connector may be in contact with a second end of the heating element. The electrical connector may be connected in series with the heating element. Preferably, the heating element may have a diameter of 0.1 millimeters to 0.5 millimeters.

[0034] The first and second electrical connectors may be located adjacent to the opening. The support element may contact the heating element at a distance further from the opening than the distance of the first and second electrical connectors from the opening. The first and second electrical connectors may be located as close as possible to the opening. The distance between the first and second electrical connectors and the opening may be less than 2 millimeters, preferably less than 1 millimeter. The distance between the second electrical connector and the opening may be less than 2 millimeters, preferably less than 1 millimeter. In this configuration, the length of the heating element between the first and second electrical connectors is shorter than in the previous configuration. As a result, a small diameter of the heating element is selected. The first and second electrical connectors, preferably the first and second electrical contact pads, may be configured to absorb a portion of the heat generated by the heating element during operation. Advantageously, this may reduce the temperature of a portion of the heating element that is not in contact with the aerosol-forming substrate or that is configured to be in contact with the aerosol-forming substrate. The first and second electrical connectors, preferably the first and second electrical contact pads, may contact the heating element at three or more locations on the heating element. The first and second electrical connectors, preferably the first and second electrical contact pads, may be connected in parallel with the heating element. Preferably, the heating element may have a diameter of 0.02 mm to 0.2 mm.

[0035] The cross-sectional area of ​​the opening may be between 4 square millimeters and 1000 square millimeters. Preferably, the cross-sectional area of ​​the opening may be between 9 square millimeters and 400 square millimeters. Most preferably, the cross-sectional area of ​​the opening may be between 16 square millimeters and 100 square millimeters. Any shape may be selected for the cross-section of the opening. Preferably, the cross-section of the opening may be circular, square, or rectangular. Advantageously, these cross-sectional shapes for the opening may be simple to manufacture.

[0036] The heater holder may be electrically insulating. The heater holder may have a thermal conductivity of 1 W / mk or less. The heater holder may comprise a heat resistant polymer. The heater holder may comprise polyetheretherketone (PEEK). The heater holder may comprise liquid crystal polymer (LCP). The heater holder may comprise ceramic. The heater holder may comprise alumina. The heater holder may comprise zirconia. Advantageously, these materials can withstand high temperatures.

[0037] The heating element may be or may include a susceptor material. The susceptor material may be configured to be inductively heated. In operation, the susceptor material may be heated by eddy currents induced in the susceptor material. Hysteresis losses may also contribute to inductive heating.

[0038] The device may not include a wicking element. After repeated heating of the aerosol-forming substrate in the aerosol-generating system, the wicking element may degrade more quickly compared to other components, such as the heating element. Degraded wicking material may need to be replaced before other components of the system, such as the heater assembly. Thus, a device without a wicking element may increase the lifespan of the device.

[0039] The heater assembly may comprise a compressible element, which may be configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0040] The compressible element may be a spring. The spring may be placed adjacent to or in contact with the lower plate of the heater holder. The compressible element may allow the heater assembly to move along the longitudinal axis of the device. In use, when the cartridge is attached to the device, the cartridge may provide a force to the heater assembly to move the heater assembly. When the cartridge is coupled to the device, the spring may be compressed. When the cartridge is disconnected from the device, the spring may be expanded. The spring may be positioned to act against the force provided by the insertion of the cartridge. Advantageously, an interference fit between the cartridge and the heater assembly may be achieved, which may reduce the possibility of leakage of the aerosol-forming substrate. The interference fit may provide more efficient heating of the aerosol-forming substrate.

[0041] The aerosol generating device may further comprise a power source. The power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery. The battery may be a nickel metal hydride battery or a nickel cadmium battery. The power source may be another form of charge storage device, such as a capacitor. The power source may be configured to provide power to a heating element, which may heat the heating element.

[0042] The power supply may be configured to provide alternating current. The power supply may include a direct current to alternating current (DC / AC) inverter for converting the DC current provided by the DC power supply into alternating current.

[0043] The power supply may be configured to provide power to the heating element for resistive heating of the heating element.The power supply may be configured to provide power to the heating element for inductive heating of the heating element.

[0044] A power source may be electrically connected to the first electrical connector and the second electrical connector. The power source may be configured to provide power to the heating element via the electrical connector. The power source may be configured to provide power to the heating element by passing an electrical current through the heating element.

[0045] The aerosol generating device may further comprise a control circuit. The control circuit may comprise a controller. The controller may be a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated circuit chip (ASIC) or other electronic control circuit. The controller may be configured to control the supply of power from the power source. The controller may be configured to regulate the supply of power from the power source to the heater assembly. Thus, the controller may control the heating of the heating element.

[0046] The heating element may be airflow activated. The heating element may be smoke activated. The aerosol generating device may include a smoke puff detector. The smoke detector may be in communication with the control circuit. The smoke detector may be configured to detect when there is airflow through the airflow passage. The control circuit may be configured to activate the heating element when airflow is detected.

[0047] The aerosol generating device may be a handheld aerosol generating device.

[0048] It would be desirable to provide a heater assembly that reduces the likelihood of hot spots occurring as compared to prior art systems.

[0049] According to a second aspect of the present disclosure, there is provided a heater assembly for an aerosol generating device, the heater assembly may comprise a heater holder with an opening, a heating element spanning at least a portion of the opening, a first electrical connector and a second electrical connector in electrical contact with the heating element, and a support element comprising a thermally conductive material in thermal contact with the heating element. The heater assembly of the second aspect may comprise any of the features of the heater assembly described with respect to the first aspect of the present disclosure. In addition, any of the features of the heater assembly of the second aspect may equally apply to the heater assembly of the first aspect.

[0050] Advantageously, a support element comprising a thermally conductive material transfers heat away from hot spots of the heating element, thus leading to a more uniform temperature along the heating element, which may reduce degradation of wicking materials adjacent to or in contact with the heating element during use of the heater assembly.

[0051] The heating assembly may be a planar heater assembly. The heating element may be a planar heating element. The heating element may be a mesh heating element. The heating element may comprise a mesh. The heating element may comprise a porous material. Advantageously, a mesh heating element, a heating element comprising a mesh, or a heating element comprising a porous material may provide a large surface area in contact with the liquid aerosol-forming substrate. This large surface area may provide efficient evaporation of the liquid aerosol-forming substrate.

[0052] The heating element may comprise at least one filament. The heating element may comprise multiple conductive filaments. As used herein, the term "filament" refers to an electrical path disposed between two electrical contacts. The at least one filament may have a round cross-section, a square cross-section, a flat cross-section, or a cross-section of any other form. Preferably, the heating element comprises a single filament. A heating element comprising a single filament may also be referred to as a heating wire. The heating element may have a diameter of 0.1 millimeters to 0.5 millimeters. The heating element may have a diameter of 0.02 millimeters to 0.2 millimeters.

[0053] The heating element, or portions thereof, may include an electrically resistive material. The heating element may be configured to be resistively heated. The heating element, or portions thereof, may include or be formed from any material having suitable electrical and mechanical properties, for example a suitable electrically resistive material.

[0054] The heating element may comprise stainless steel, which may provide the heating element with desirable mechanical properties, corrosion resistance, and high electrical resistance.

[0055] The heating element may include a ferrimagnetic material. The heating element may include a ferromagnetic material. The heating element may be formed of a ferrimagnetic or ferromagnetic material. At least a portion of the heating element may be formed of a ferrimagnetic or ferromagnetic material. The electrical resistance of the heating element may increase as the frequency of the alternating current applied to the heating element increases. The use of a heating element including a ferrimagnetic or ferromagnetic material may advantageously generate more heat locally without having to increase the electrical resistance of the heating element and thus reduce the diameter of the heating element. Reducing the diameter may compromise the mechanical strength of the heating element.

[0056] The total electrical resistance of the heating element may be from 0.1 ohms to 5 ohms, preferably from 0.4 ohms to 2 ohms. Advantageously, an electrical resistance within this range enables the heating element to reach a suitable temperature for vaporization of the aerosol-forming substrate.

[0057] The heating element may be coated with a corrosion resistant material, which may increase the lifespan of the heating element. The heating element may be coated with a ceramic material.

[0058] The support element may be configured to absorb heat generated by the heating element. The support element may provide mechanical support to the heating element. The support element may laterally support the heating element. The support element may include a thermally conductive material in thermal contact with the heating element. The support element may be configured to absorb heat generated by the heating element. Advantageously, the presence of a support element including a thermally conductive material may reduce the temperature of the heating element in areas where the heating element is not in contact with the wicking material or the aerosol-forming substrate. This may reduce overheating of the heating element and preferably prolong the life of the heating element. In addition, this may reduce or slow down the degradation of the wicking material in contact with the heating element. Advantageously, the support element conducts heat away from hot spots of the heating element, leading to a more uniform temperature along the heating element. This may reduce the degradation of the wicking material adjacent to or in contact with the heating element during use of the heater assembly.

[0059] The support element may comprise at least one of aluminum, copper, brass, gold, silver, or a thermally conductive ceramic. Advantageously, these materials have high thermal conductivity.

[0060] The thermal conductivity of the support element may be at least 10 W / mK. Preferably, the thermal conductivity of the support element may be at least 50 W / mK. Preferably, the thermal conductivity of the support element may be at least 200 W / mK.

[0061] The support element may comprise at least one support pin. The heating element may engage with at least one support pin. The support element may comprise at least 4, at least 6, at least 8, at least 10, or at least 12 support pins. The heating element may engage with at least one support pin. The heating element may be wound or shaped to be wound around at least one support pin. The heating element may be a single filament, the filament going around each of the support pins.

[0062] The at least one support pin may be cylindrical. The at least one support pin may have a diameter of 0.5 mm to 5 mm, preferably 1 mm to 2 mm.

[0063] The heater holder may provide mechanical support to the support element. The heater holder may comprise an upper plate and a lower plate. The heating element may be located between the upper and lower plates. Advantageously, a heater holder comprising an upper and lower plate with a heating element located therebetween may be straightforward to manufacture. The support element may be attached to the heater holder. The support element may be mechanically fixed to the heater holder. The support element may be pressed into the heater holder. The support element may be fixed to the heater holder using an adhesive such as glue. The support element may be mechanically fixed to the lower plate. The support element may be mechanically fixed to the upper plate. There may be an interference fit between the support element and the heater holder.

[0064] The upper plate may be mechanically secured to the lower plate. The upper plate may be secured to the lower plate using fasteners. Suitable fasteners may be screws or rivets. The upper plate may be secured to the lower plate using an adhesive. The upper plate may be secured to the lower plate by plastic welding the upper and lower plates together. The upper plate may be secured to the lower plate by overmolding.

[0065] The heater holder may have an opening defined therethrough. The opening may be defined through the upper plate and the lower plate. The heating element may span at least a portion of the opening. The opening may be configured to allow the aerosol-forming substrate to flow between the second side of the heater assembly and the first side of the heater assembly. The opening may be configured to allow gases, such as air and vapor generated from the aerosol-forming substrate, to flow between the second side of the heater assembly and the first side of the heater assembly.

[0066] The first electrical connector and the second electrical connector may be configured to provide electrical power to the heating element. The electrical connector may be placed in electrical contact with the heating element. The first electrical connector may include a first contact pad and the second electrical connector may include a second electrical contact pad, the first electrical contact pad and the second electrical contact pad configured to be in electrical contact with the heating element. The electrical connector may extend outside the heater assembly to enable provision of electrical energy from a power source to the electrical connector and thus to the heating element. In operation, the heating element may be heated as a result of an electrical current passing through the heating element. The first electrical connector and the second electrical connector may be positioned on opposite sides of the heating element. The electrical current passing from the first electrical connector to the second electrical connector may pass through the heating element.

[0067] The support element may be placed adjacent to the opening. The support element may be placed as close as possible to the opening. The distance between the support element and the opening may be less than 2 mm, preferably less than 1 mm. Advantageously, this may minimize the overall length of the heating element. The length of the heating element that does not span the opening may also be reduced. The percentage of the heating element that spans the opening may be increased. Increasing the percentage of the heating element that spans the opening may increase the percentage of the second side of the heating element that is configured to contact the cartridge and receive the aerosol-forming substrate. Advantageously, less material may be required to manufacture the heating element while not reducing the performance of the heating element. Hot spots in the heating element may be more likely to occur in the portion of the heating element that contacts the heater holder. Thus, the support element may be placed adjacent to the opening where the heating element will contact the heater holder. This may reduce the occurrence of hot spots in the heating element during litigation of the heater assembly.

[0068] The electrical connector may be in electrical contact with the heating element at a distance from the opening greater than the distance of the support element from the opening. The first electrical connector may be in electrical contact with a first end of the heating element. The second electrical connector may be in contact with a second end of the heating element. The electrical connector may be connected in series with the heating element. Preferably, the heating element may have a diameter of 0.1 millimeters to 0.5 millimeters.

[0069] The first and second electrical connectors may be located adjacent to the opening. The support element may contact the heating element at a distance further from the opening than the distance of the first and second electrical connectors from the opening. The first and second electrical connectors may be located as close as possible to the opening. The distance between the first and second electrical connectors and the opening may be less than 2 millimeters, preferably less than 1 millimeter. The distance between the second electrical connector and the opening may be less than 2 millimeters, preferably less than 1 millimeter. In this configuration, the length of the heating element between the first and second electrical connectors is shorter than in the previous configuration. As a result, a small diameter of the heating element is selected. The first and second electrical connectors, preferably the first and second electrical contact pads, may be configured to absorb a portion of the heat generated by the heating element during operation. Advantageously, this may reduce the temperature of a portion of the heating element that is not in contact with the aerosol-forming substrate or that is configured to be in contact with the aerosol-forming substrate. The first and second electrical connectors, preferably the first and second electrical contact pads, may contact the heating element at three or more locations on the heating element. The first and second electrical connectors, preferably the first and second electrical contact pads, may be connected in parallel with the heating element. Preferably, the heating element may have a diameter of 0.02 mm to 0.2 mm.

[0070] The cross-sectional area of ​​the opening may be between 4 square millimeters and 1000 square millimeters. Preferably, the cross-sectional area of ​​the opening may be between 9 square millimeters and 400 square millimeters. Most preferably, the cross-sectional area of ​​the opening may be between 16 square millimeters and 100 square millimeters. Any shape may be selected for the cross-section of the opening. Preferably, the cross-section of the opening may be circular, square, or rectangular. Advantageously, these cross-sectional shapes for the opening may be simple to manufacture.

[0071] The heater holder may be electrically insulating. The heater holder may be thermally insulating. The heater holder may have a thermal conductivity of 1 W / mk or less. The heater holder may comprise a heat resistant polymer. The heater holder may comprise polyetheretherketone (PEEK). The heater holder may comprise liquid crystal polymer (LCP). The heater holder may comprise ceramic. The heater holder may comprise alumina. The heater holder may comprise zirconia. Advantageously, these materials can withstand high temperatures, preferably higher than those that may be reached during normal operation of the heating element.

[0072] The heater assembly may comprise a compressible element, which may be configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0073] The compressible element may be a compressible wicking element. The compressible wicking element may be located on the second side of the heater assembly.

[0074] The compressible element may be a spring. The spring may be placed adjacent to or in contact with the lower plate of the heater holder. The compressible element may allow the heater assembly to move along the longitudinal axis of the device. In use, when the cartridge is attached to the device, the cartridge may provide a force to the heater assembly to move the heater assembly. When the cartridge is coupled to the device, the spring may be compressed. When the cartridge is disconnected from the device, the spring may be expanded. The spring may be positioned to act against the force provided by the insertion of the cartridge. Advantageously, an interference fit between the cartridge and the heater assembly may be achieved, which may reduce the possibility of leakage of the aerosol-forming substrate. The interference fit may provide more efficient heating of the aerosol-forming substrate.

[0075] According to a third aspect of the present disclosure, there is provided a cartridge configured to couple with an aerosol generating device as described in the first aspect of the present disclosure. The cartridge may comprise an aerosol-forming substrate and a wicking material in fluid communication with the aerosol-forming substrate. The wicking material may form part of an external surface of the cartridge and may be configured to contact the aerosol generating device.

[0076] The cartridge may not include a heater assembly. The cartridge may not include a heating element. Advantageously, the cost and complexity of manufacturing the cartridge may be reduced compared to prior art cartridges, such as cartridges that include a wicking material and a heating element in contact with the wicking material. The cartridge may be discarded, usually after numerous heating cycles, when the wicking material becomes degraded. Advantageously, the cartridge may be disconnected from the aerosol generating device, and the cartridge may be discarded. The aerosol generating device and the components contained within the aerosol generating device may be reused.

[0077] The cartridge may include a cartridge airflow passage defined between the cartridge air inlet and the cartridge air outlet. When negative pressure is applied to the cartridge air outlet, air is drawn into the cartridge air inlet and an airflow is formed in the airflow passage from the cartridge air inlet to the cartridge air outlet.

[0078] The cartridge may comprise a mouthpiece. The mouthpiece may be a removable mouthpiece. The mouthpiece may comprise a cartridge air outlet. In use, when the cartridge is engaged with an aerosol generating device, a user may inhale through the mouthpiece of the cartridge.

[0079] The aerosol-forming substrate may be a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be solid or liquid, or may contain both solid and liquid components. The aerosol-forming substrate may be a fluid. The aerosol-forming substrate may be a gel. The gel may be solid at room temperature. In this context, "solid" means that the gel has a stable size and shape and does not flow. In this context, room temperature means 25 degrees Celsius. Preferably, the aerosol-forming substrate is a liquid.

[0080] The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material that contains volatile tobacco flavour compounds that are released from the aerosol-forming substrate upon heating. The aerosol-forming substrate may comprise a non-tobacco-containing material.

[0081] The aerosol-forming substrate may include 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 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, and glycerin), 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, and the like). Preferred aerosol formers are polyhydric alcohols or mixtures thereof (such as triethylene glycol, 1,3-butanediol, and most preferably glycerin). The aerosol-forming substrate may include other additives and ingredients, such as flavoring agents.

[0082] The cartridge may comprise a reservoir for containing the aerosol-forming substrate. The reservoir may have any size and shape suitable for containing the aerosol-forming substrate within the cartridge. The wicking material may be in fluid communication with the aerosol-forming substrate contained within the reservoir.

[0083] The reservoir may comprise at least one opening. The at least one opening may be in contact with the wicking material. The wicking material may be in fluid communication with the reservoir via the at least one opening. The at least one opening may be configured to allow the aerosol-forming substrate to flow from the reservoir to the wicking material. The at least one opening may be configured to allow gas to flow from the wicking material to the reservoir. During use of the cartridge, the aerosol-forming substrate may flow from the reservoir to the wicking material and gas, such as air, may flow through the wicking material to the reservoir. This may allow pressure to balance within the cartridge.

[0084] The cartridge may include a wicking portion. The wicking portion may include a wicking material. The wicking material may form part of an exterior surface of the cartridge and may be configured to contact a heating element of the aerosol generating device.

[0085] The wicking material may include or may be a material that is wetted by the aerosol-forming substrate or configured to be wetted by the aerosol-forming substrate. The wicking material may have a fibrous or spongy structure. The wicking material may be a capillary material. A capillary material is a material that actively transports liquid from one end of the material to another. 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 aerosol-forming substrate. 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 aerosol-forming substrate can be transported by capillary action. The capillary material may comprise any suitable material or combination of materials. Examples of suitable materials are sponge or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, foamed metal or plastic materials, fibrous materials, such as 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 capillary action and porosity to be used with different physical properties of the aerosol-forming substrate. The aerosol-forming substrate has physical properties including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure that allow the aerosol-forming substrate to be transported through the capillary material by capillary action.

[0086] Preferably, the wicking material may be a ceramic wick. The ceramic wick may comprise, or preferably consist of, a ceramic material. Preferably, when the wicking element is a ceramic wick, the wicking element may comprise a porous ceramic. The porous ceramic wick may comprise an open pore ceramic. The ceramic wick may be rigid. The ceramic wick may not deform when the cartridge is connected to the aerosol generating device.

[0087] The cartridge may further include a compressible element. The compressible element of the cartridge may be a compressible wicking element. The compressible wicking element may be a wicking material. The compressible wicking element may be disposed adjacent to the wicking material.

[0088] The compressible wicking element may comprise or preferably consist of a compressible material. For example, the compressible wicking element preferably comprises a spongy or foam material. The compressible wicking element may form part of the device coupling and may be configured to contact the aerosol generating device. The compressible wicking element may be compressed when the cartridge is coupled to the aerosol generating device. This advantageously ensures that the contact area between the compressible wicking element and the device is maximized, and may therefore improve the transport of the aerosol-forming substrate to the heating element and improve heating efficiency. Preferably, the compressible wicking element may comprise or consist of an elastic material. Such a wicking element may advantageously return to its original shape after being compressed. Thus, when the cartridge is disconnected from the aerosol generating device, the compressible wicking element may return to its original shape.

[0089] The wicking material may have any suitable cross-sectional shape. The wicking material may have a square, rectangular, or circular cross-section. Wicking materials of this shape may be simple to manufacture. Preferably, the wicking material is cylindrical.

[0090] The wicking material may have a width of from 2 millimeters to 32 millimeters, preferably from 3 millimeters to 20 millimeters, more preferably from 4 millimeters to 10 millimeters. If the wicking element is cylindrical, the values ​​for the width correspond to the values ​​for the diameter of the cylindrical wicking element.

[0091] The cartridge may comprise a device connection part. The device connection part may be configured to connect with an aerosol generating device. The device connection part may comprise a cartridge air inlet. The device connection part may be provided at an end of the cartridge opposite the cartridge air outlet. The device connection part may comprise a wicking material. The wicking material may protrude from a surface of the device connection part. This may allow the wicking material to easily contact the cartridge connection part of the device. In particular, this may allow the wicking material to easily contact the heating element of the device. The wicking material may protrude from a surface of the device connection part by at least 1 millimeter, preferably by at least 2 millimeters, more preferably by at least 3 millimeters.

[0092] The cartridge may further comprise a removable seal. The removable seal may be configured to cover the wicking material prior to use of the cartridge. Advantageously, the removable seal may protect the wicking material from damage or contamination prior to use of the cartridge. The removable seal may also prevent exposure of the wicking material, and thus the aerosol-forming substrate, to air prior to use of the cartridge. Advantageously, the removable seal may reduce evaporation of the aerosol-forming substrate from the wicking material before the cartridge is coupled to an aerosol generating device. The removable seal may advantageously prevent loss or leakage of the aerosol-forming substrate from the cartridge prior to use of the cartridge, particularly during storage or transport. The removable seal may be configured to be removed by a user prior to use of the cartridge. The removable seal may be configured to be removed by a user prior to coupling of the cartridge to an aerosol generating device.

[0093] The cartridge may further comprise a protruding wall. The protruding wall may protrude from a surface of the device coupling portion. The protruding wall may protrude from a surface of the device coupling portion by at least 1 millimeter, preferably by at least 2 millimeters, more preferably by at least 3 millimeters. The protruding wall may surround a periphery of the device coupling portion. The protruding wall may be configured to contact or be received by the aerosol generation device. The protruding wall may be configured to contact or be received by the cartridge coupling portion of the aerosol generation device.

[0094] The protruding wall may be configured to protrude from the surface of the device interface portion by at least the same amount as the wicking material. The protruding wall may be configured to protrude from the surface of the device interface portion by more than the wicking material. Advantageously, the protruding wall may protect the wicking material from shock or damage. The protruding wall may be configured to engage the aerosol generating device. The removable seal may be attached to the protruding wall. The removable seal may be attached to the protruding wall by an adhesive. The removable seal may not contact the wicking material.

[0095] The cartridge air inlet may comprise a separation wall that protrudes from the surface of the device connection portion. The separation wall may protrude from the surface of the device connection portion by at least 1 millimeter, preferably at least 2 millimeters, more preferably at least 3 millimeters. The separation wall may protrude from the surface of the device connection portion by at least the same amount as the wicking material. The separation wall may protrude from the surface of the device connection portion by more than the wicking material. The separation wall may protrude from the surface of the device connection portion by less than the protruding wall. The separation wall may protrude from the surface of the device connection portion by the same amount as the protruding wall. A removable seal may cover the cartridge air inlet. Advantageously, this may protect the cartridge air inlet from contaminants, particularly during storage and transport of the cartridge, before a user removes the removable seal. The separation wall may be configured to engage with an aerosol generating device.

[0096] It would be desirable to provide an aerosol generation system that reduces degradation of the wicking material as compared to prior art systems and requires less frequent disposal of the cartridge and heater assembly.

[0097] According to a fourth aspect of the present disclosure there is provided an aerosol generation system, which may comprise any of the features of the aerosol generator, heater assembly or cartridge described in relation to the first, second or third aspect of the present disclosure.

[0098] The aerosol generation system may comprise a cartridge. The cartridge may comprise an aerosol-forming substrate in fluid communication with a wicking material, the wicking material forming part of an exterior surface of the cartridge. The aerosol generation system may further comprise an aerosol generation device. The aerosol generation device may comprise a cartridge interface for engaging a cartridge including the aerosol-forming substrate, an airflow passage defined between the device air inlet and the device air outlet, and a heater assembly. The heater assembly may comprise a fluid-permeable heating element configured to heat the aerosol-forming substrate from the cartridge. The heater assembly may comprise a first side and a second side, the first side facing opposite the second side, the first side forming at least a part of a surface of a wall of the airflow passage, and the second side forming part of the cartridge interface and configured to receive the aerosol-forming substrate in contact with the wicking material of the cartridge.

[0099] Advantageously, when the cartridge requires replacement, the heater assembly may be retained in the device instead of being removed and discarded. The heater assembly may be more expensive to manufacture compared to other elements of the cartridge, so it may be advantageous to prevent unnecessary disposal of the heater assembly. Locating the heater assembly in the device may mean that the cartridge does not include a heater assembly. Thus, the cartridge is less expensive to manufacture and simpler to manufacture compared to a cartridge that contains a heater assembly.

[0100] The aerosol-forming substrate may be a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be solid or liquid, or may contain both solid and liquid components. The aerosol-forming substrate may be a fluid. The aerosol-forming substrate may be a gel. The gel may be solid at room temperature. In this context, "solid" means that the gel has a stable size and shape and does not flow. In this context, room temperature means 20 degrees Celsius. Preferably, the aerosol-forming substrate is a liquid.

[0101] The cartridge may comprise a reservoir for containing the aerosol-forming substrate. The reservoir may have any size and shape suitable for containing the aerosol-forming substrate within the cartridge. The wicking material may be in fluid communication with the aerosol-forming substrate contained within the reservoir.

[0102] The reservoir may comprise at least one opening. The at least one opening may be in contact with the wicking material. The wicking material may be in fluid communication with the reservoir via the at least one opening. The at least one opening may be configured to allow the aerosol-forming substrate to flow from the reservoir to the wicking material. The at least one opening may be configured to allow gas to flow from the wicking material to the reservoir. During use of the cartridge, the aerosol-forming substrate may flow from the reservoir to the wicking material and gas, such as air, may flow through the wicking material to the reservoir. This may allow pressure to balance within the cartridge.

[0103] The cartridge may include a wicking portion. The wicking portion may include a wicking material. The wicking material may form part of an exterior surface of the cartridge and may be configured to contact a heating element of the aerosol generating device.

[0104] The wicking material may include or be a material that is wetted by or configured to be wetted by the aerosol-forming substrate. The wicking material may have a fibrous or spongy structure. The wicking material may be a capillary material.

[0105] The wicking material may be a ceramic wick. The ceramic wick may comprise, or preferably consists of, a ceramic material. Preferably, when the wicking element is a ceramic wick, the wicking element may comprise a porous ceramic. The porous ceramic wick may comprise an open pore ceramic. The ceramic wick may be rigid. The ceramic wick may not deform when the cartridge is connected to the aerosol generating device.

[0106] The cartridge may comprise a cartridge air inlet and a cartridge air outlet, the cartridge air inlet being aligned with the device air outlet. The cartridge air outlet may comprise a mouthpiece.

[0107] The device air inlet may be defined in a side wall of the aerosol generation device. The device air outlet may be defined in an end wall of the aerosol generation device. The side wall of the aerosol generation device may extend perpendicular to the end wall of the aerosol generation device. The device air outlet may be configured to align with an opening in the cartridge.

[0108] When the cartridge is coupled to the device, an airflow passage may be formed from the device air inlet to the cartridge air outlet. During use of the aerosol generation system, a user may breathe on the cartridge air outlet. This may draw air into the device air inlet, past the heating element, through the device air outlet, through the cartridge air inlet, and out the cartridge air outlet to the user.

[0109] The second side of the heater assembly may be located outside of the airflow passage. The second side of the heater assembly may be configured to contact a wicking material of the cartridge. The heater assembly may be a planar heater assembly.

[0110] The heater assembly may comprise a heater holder. The heater holder may have an opening defined therethrough. The heater holder may comprise an upper plate and a lower plate. The opening may be defined through the upper plate and the lower plate. The heating element may span at least a portion of the opening. The opening may be configured to allow the aerosol-forming substrate to flow between a second side of the heater assembly and a first side of the heater assembly. The opening may be configured to allow gases, such as air and vapor generated from the aerosol-forming substrate, to flow between the second side of the heater assembly and the first side of the heater assembly.

[0111] The wicking material may have a shape corresponding to the shape of the opening of the heater assembly. The wicking material may have a cross-sectional area corresponding to the cross-sectional area of ​​the opening of the heater assembly for the aerosol generating device. A cross-section of the wicking material corresponding to the cross-sectional area of ​​the opening of the heater assembly may advantageously allow good contact between the wicking material and the heating element of the heater assembly. The wicking material may have a cross-sectional area that is at least 2, 3, 4, or 5 percent smaller than the cross-sectional area of ​​the opening of the heater assembly for the aerosol generating device. This may allow the wicking material to be easily received by the opening of the heater assembly. The wicking material may have any suitable cross-sectional shape. The wicking material may have a square, rectangular, or circular cross-section. A wicking material of this shape may be simple to manufacture. Preferably, the wicking material is cylindrical.

[0112] The wicking material may have a width of from 2 millimeters to 32 millimeters, preferably from 3 millimeters to 20 millimeters, more preferably from 4 millimeters to 10 millimeters. If the wicking element is cylindrical, the values ​​for the width correspond to the values ​​for the diameter of the cylindrical wicking element.

[0113] The heater assembly may be configured to contact the wicking portion of the cartridge. The heating element may be configured to contact the wicking portion of the cartridge.

[0114] The heating element may be a mesh heating element. The heating element may comprise a mesh. The heating element may comprise a porous material. Advantageously, a mesh heating element, a heating element comprising a mesh, or a heating element comprising a porous material may provide a large surface area in contact with the liquid aerosol-forming substrate. This large surface area may provide efficient evaporation of the liquid aerosol-forming substrate.

[0115] The heating element may comprise at least one filament. The heating element may comprise multiple conductive filaments. As used herein, the term "filament" refers to an electrical path disposed between two electrical contacts. The at least one filament may have a round cross-section, a square cross-section, a flat cross-section, or a cross-section of any other form. Preferably, the heating element comprises a single filament. A heating element comprising a single filament may also be referred to as a heating wire. The heating element may have a diameter of 0.1 millimeters to 0.5 millimeters. The heating element may have a diameter of 0.02 millimeters to 0.2 millimeters.

[0116] The heating element, or portions thereof, may comprise an electrically resistive material. The heating element may be configured to be resistively heated. In other words, the heating element may be configured to generate heat when an electric current is passed through the heating element.

[0117] Preferably, the heating element comprises stainless steel, which may provide the heating element with desirable mechanical properties, corrosion resistance, and high electrical resistance.

[0118] The heater assembly may comprise a support element. The support element may provide mechanical support to the heating element. The support element may laterally support the heating element. The support element may comprise a thermally conductive material in thermal contact with the heating element. The support element may be configured to absorb heat generated by the heating element. The support element comprising a thermally conductive material may conduct heat away from the heating element in areas where the heating element is in contact with the support element. Advantageously, the presence of a support element comprising a thermally conductive material may reduce the temperature of the heating element in areas where the heating element is not in contact with the wicking material or the aerosol-forming substrate. This may reduce overheating of the heating element and preferably prolong the life of the heating element. Additionally, this may reduce or slow down the degradation of the wicking material in contact with the heating element. Advantageously, the support element comprising a thermally conductive material may reduce the likelihood of hot spots forming within the heating element. Reducing the hot spots may increase the life of the heating element. Reducing the hot spots may also increase the life of the wicking material of the cartridge.

[0119] The heater assembly may comprise a compressible element, which may be configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0120] The compressible element may be a spring.

[0121] The compressible element may be a compressible wicking element.

[0122] The cartridge may comprise a cartridge housing. The device may comprise a device housing. The cartridge housing and the device housing may be rigid. The cartridge housing may engage with the device housing. When the device housing engages with the cartridge housing, the compressible element may be compressed.

[0123] The aerosol generation system may further comprise a first electrical connector and a second electrical connector. The first electrical connector and the second electrical connector may be configured to provide electrical power to the heating element. The electrical connector may be placed in electrical contact with the heating element. The first electrical connector may comprise a first contact pad and the second electrical connector may comprise a second electrical contact pad, the first electrical contact pad and the second electrical contact pad configured to be in electrical contact with the heating element. The electrical connector may extend outside the heater assembly to enable provision of electrical energy from a power source to the electrical connector and thus to the heating element. In operation, the heating element may be heated as a result of electrical current passing through the heating element. The first electrical connector and the second electrical connector may be positioned on opposite sides of the heating element. Electrical current passing from the first electrical connector to the second electrical connector may pass through the heating element.

[0124] The aerosol generating system may further comprise a power source. The power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery. The battery may be a nickel metal hydride battery or a nickel cadmium battery. The power source may be another form of charge storage device, such as a capacitor. The power source may be configured to provide power to a heating element, which may heat the heating element.

[0125] The power supply may be configured to provide power to the heating element to resistively heat the heating element.

[0126] A power source may be electrically connected to the first electrical connector and the second electrical connector. The power source may be configured to provide power to the heating element via the electrical connector. The power source may be configured to provide power to the heating element by passing an electrical current through the heating element.

[0127] The aerosol generating system may further comprise a control circuit. The control circuit may comprise a controller. The controller may be a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated circuit chip (ASIC) or other electronic control circuit. The controller may be configured to control the supply of power from the power source. The controller may be configured to regulate the supply of power from the power source to the heater assembly. Thus, the controller may control the heating of the heating element.

[0128] The aerosol generation system may be smoke activated. The heating element may be airflow activated. The heating element may be smoke activated. The aerosol generation system may include a smoke puff detector. The smoke detector may be in communication with the control circuit. The smoke detector may be configured to detect when there is airflow through the airflow passage. The control circuit may be configured to activate the heating element when airflow is detected.

[0129] The aerosol generating system may be a handheld aerosol generating system. The aerosol generating system may have a size comparable to a conventional cigar or cigarette. The aerosol generating system may have a total length of about 30 mm to about 150 mm. The aerosol generating system may have an outer diameter of about 5 mm to about 30 mm.

[0130] As used herein, the term "heating element" refers to an element of a heater assembly that is configured to be heated. For example, the term "heating element" may refer to an element that is configured to be heated to at least 50, 100, 150, 200, 250, or 300 degrees Celsius.

[0131] As used herein, the term "coupled or coupleable" is used to mean that the cartridge and device can be coupled to and decoupled from each other without significant damage to either the cartridge or the device.

[0132] 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 of the features described above, for example with any one or more of the features of other examples, embodiments, or aspects described herein.

[0133] Example 1: An aerosol generating device for connection to a cartridge, comprising: a cartridge connecting portion for engaging a cartridge containing an aerosol-forming substrate; an airflow passage defined between the air inlet and the air outlet; an aerosol generating device comprising: a heater assembly comprising a fluid-permeable heating element configured to heat an aerosol-forming substrate from a cartridge, the heater assembly having a first side and a second side, the first side facing opposite the second side, the first side forming at least a portion of a surface of a wall of an airflow passage, and the second side forming a portion of a cartridge connecting portion and configured to contact the cartridge and receive the aerosol-forming substrate;

[0134] Example 2: An aerosol generating device according to Example 1, wherein the air inlet is defined in a side wall of the device.

[0135] Example 3: An aerosol generating device according to example 2, wherein the air outlet is defined in an end wall of the device.

[0136] Example 4: An aerosol generating device according to example 3, wherein the side walls of the device extend perpendicular to the end walls of the device.

[0137] Example 5: An aerosol generating device according to any one of Examples 1 to 4, wherein the second side of the heater assembly is located outside the airflow passage.

[0138] Example 6: An aerosol generating device according to any one of Examples 1 to 5, wherein the air outlet is configured to align with an opening in the cartridge.

[0139] Example 7: An aerosol generating device according to any one of Examples 1 to 6, wherein the heating assembly is a planar heater assembly.

[0140] Example 8: The aerosol generating device according to any one of Examples 1 to 7, wherein the heating element is a planar heating element.

[0141] Example 9: An aerosol generating device according to Example 8, wherein the heating element is perpendicular to the longitudinal axis of the device.

[0142] Example 10: An aerosol generating device according to any one of Examples 1 to 9, wherein the heating element is provided with a mesh.

[0143] Example 11: An aerosol generating device according to any one of Examples 1 to 10, wherein the heating element comprises a porous material.

[0144] Example 12: An aerosol generating device according to any one of Examples 1 to 11, wherein the heating element comprises at least one filament.

[0145] Example 13: An aerosol generating device according to Example 12, wherein at least one filament has a diameter of 0.1 millimeters to 0.5 millimeters.

[0146] Example 14: An aerosol generating device according to Example 12, wherein at least one filament has a diameter between 0.02 millimeters and 0.2 millimeters.

[0147] Example 15: The aerosol generating device according to any one of Examples 1 to EX14, wherein the total electrical resistance of the heating element is 0.1 ohms to 5 ohms, preferably 0.4 ohms to 2 ohms.

[0148] Example 16: An aerosol generating device according to any one of Examples 1 to 15, wherein the heating element comprises stainless steel.

[0149] Example 17: An aerosol generating device according to any one of Examples 1 to 16, wherein the heating element comprises a ferrimagnetic or ferromagnetic material.

[0150] Example 18: An aerosol generating device according to any one of Examples 1 to 17, wherein the heating element is coated with a corrosion-resistant material.

[0151] Example 19: An aerosol generating device according to any one of Examples 1 to 18, wherein the heating element is coated with a ceramic material.

[0152] Example 20: An aerosol generating device according to any one of Examples 1 to 19, wherein the heater assembly is configured to contact a wicking portion within the cartridge.

[0153] Example 21: An aerosol generating device according to any one of Examples 1 to 20, wherein the heater assembly comprises a support element, the support element comprising a thermally conductive material in thermal contact with the heating element.

[0154] Example 22: An aerosol generating device according to example 21, wherein the support element is configured to absorb heat generated by the heating element.

[0155] Example 23: An aerosol generating device according to Example 21 or 22, wherein the support element comprises at least one of aluminum, copper, brass, gold, silver, or a thermally conductive ceramic.

[0156] Example 24: An aerosol generating device according to any of Examples 21 to 23, wherein the thermal conductivity of the support element is at least 10 W / mK.

[0157] Example 25: An aerosol generating device according to Example 24, wherein the thermal conductivity of the support element is at least 50 W / mK.

[0158] Example 26: An aerosol generating device according to example 25, wherein the thermal conductivity of the support element is at least 200 W / mK.

[0159] Example 27: An aerosol generating device according to any one of Examples 21 to 26, wherein the support element comprises at least one support pin.

[0160] Example 28: An aerosol generating device according to example 27, wherein the heating element is engaged with at least one support pin.

[0161] Example 29: An aerosol generating device according to example 27 or 28, wherein at least one support pin is cylindrical.

[0162] Example 30: An aerosol generating device according to example 29, wherein at least one support pin has a diameter of 0.5 millimeters to 5 millimeters, preferably 1 to 2 millimeters.

[0163] Example 31: An aerosol generating device according to any one of Examples 1 to 30, wherein the heater assembly further comprises a heater holder.

[0164] Example 32: An aerosol generating device according to Example 31, wherein the heater holder comprises an upper plate and a lower plate.

[0165] Example 33: An aerosol generating device according to Example 32, wherein the heating element is placed between the upper plate and the lower plate.

[0166] Example 34: An aerosol generating device according to any of Examples 31-33, wherein the heater holder has an opening defined therethrough.

[0167] Example 35: An aerosol generating device according to Example 34, wherein an aperture is defined through the upper plate and the lower plate.

[0168] Example 36: An aerosol generating device according to example 34 or 35, wherein the heating element spans at least a portion of the opening.

[0169] Example 37: An aerosol generating device according to any one of Examples 34 to 36, wherein the support element is positioned adjacent to the opening.

[0170] Example 38: An aerosol generating device according to any one of Examples 1 to 37, further comprising a first electrical connector and a second electrical connector, the first electrical connector and the second electrical connector being configured to supply power to the heating element and configured to resistively heat the heating element.

[0171] Example 39: An aerosol generating device according to example 38, wherein the electrical connector is placed in electrical contact with the heating element at a distance further from the opening than the distance from the opening to the support element.

[0172] Example 40: An aerosol generating device according to example 38, wherein the first electrical connector and the second electrical connector are positioned adjacent to the opening.

[0173] Example 41: An aerosol generating device according to example 40, wherein the support element contacts the heating element at a distance from the opening that is greater than the distance from the opening of the first electrical connector and the second electrical connector.

[0174] Example 42: An aerosol generating device according to any one of Examples 34 to 41, in which the cross-sectional area of ​​the opening is between 4 square millimeters and 1000 square millimeters.

[0175] Example 43: An aerosol generating device according to Example 42, in which the cross-sectional area of ​​the opening is between 9 square millimeters and 400 square millimeters.

[0176] Example 44: An aerosol generating device according to Example 43, in which the cross-sectional area of ​​the opening is 16 square millimeters to 100 square millimeters.

[0177] Example 45: An aerosol generating apparatus according to any one of Examples 31 to 44, wherein the heater holder is electrically insulating.

[0178] Example 46: An aerosol generating device according to Example 45, wherein the heater holder has a thermal conductivity of 1 W / mk or less.

[0179] Example 47: An aerosol generating device according to example 45 or 46, wherein the heater holder comprises a heat-resistant polymer.

[0180] Example 48: An aerosol generating device according to any one of Examples 45 to 47, wherein the heater holder comprises PEEK.

[0181] Example 49: An aerosol generating device according to any one of Examples 45 to 48, wherein the heater holder comprises an LCP.

[0182] Example 50: An aerosol generating device according to any one of Examples 45 to 49, wherein the heater holder comprises ceramic.

[0183] Example 51: An aerosol generating device according to Example 50, wherein the heater holder comprises alumina.

[0184] Example 52: An aerosol generating device according to example 50 or 51, wherein the heater holder comprises zirconia.

[0185] Example 53: An aerosol generating device according to any one of Examples 1 to 52, wherein the heater assembly comprises a wicking element.

[0186] Example 54: An aerosol generating device according to any one of Examples 1 to 53, wherein the heating element comprises a susceptor material configured to be inductively heated.

[0187] Example 55: An aerosol generating device according to any one of Examples 1 to 54, further comprising a power source.

[0188] Example 56: An aerosol generating device according to any one of Examples 1 to 54, further comprising a control circuit.

[0189] Example 57: An aerosol generating device according to any one of Examples 1 to 56, wherein the aerosol generating device is a handheld aerosol generating device.

[0190] Example 58: An aerosol generating device according to any one of Examples 1 to 57, wherein the heating element is airflow-activated.

[0191] Example 59: An aerosol generating device according to any one of Examples 1 to 58, wherein the heating element is of a suction-activated type.

[0192] Example 60: An aerosol-generating device according to any one of Examples 1 to 59, wherein the heating element is configured to heat the fluid aerosol-forming substrate.

[0193] Example 61: An aerosol-generating device according to any one of Examples 1 to 60, wherein the heating element is configured to heat the liquid aerosol-forming substrate.

[0194] Example 62: An aerosol generating device according to any one of Examples 1 to 61, wherein the heater assembly comprises a compressible element, the compressible element being configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0195] Example 63: An aerosol generating device according to Example 62, wherein the compressible element is a spring.

[0196] Example 64: An aerosol generating device according to Example 62, wherein the compressible element is a compressible wicking element disposed on the second side of the heater assembly.

[0197] Example 65: A heater assembly for an aerosol generating device, comprising: a heater holder having an opening; a heating element spanning at least a portion of the opening; a first electrical connector and a second electrical connector in electrical contact with the heating element; a support element comprising a thermally conductive material in thermal contact with the heating element.

[0198] Example 66: The heater assembly according to example 65, wherein the heater assembly is a planar heater assembly.

[0199] Example 67: A heater assembly according to Example 65 or 66, wherein the heating element is a planar heating element.

[0200] Example 68: A heater assembly according to any one of Examples 65 to 67, wherein the heating element comprises a mesh.

[0201] Example 69: A heater assembly according to any one of Examples 65-68, wherein the heating element comprises a porous material.

[0202] Example 70: A heater assembly according to any one of Examples 65-69, wherein the heating element comprises at least one filament.

[0203] Example 71: A heater assembly according to any one of Examples 65-70, wherein at least one filament has a diameter between 0.1 millimeters and 0.5 millimeters.

[0204] Example 72: A heater assembly according to any one of Examples 65-70, wherein at least one filament has a diameter between 0.02 millimeters and 0.2 millimeters.

[0205] Example 73: A heater assembly according to any one of Examples 65 to 72, wherein the total electrical resistance of the heating element is from 0.1 ohms to 5 ohms, preferably from 0.4 ohms to 2 ohms.

[0206] Example 74: The heater assembly according to any one of Examples 65-73, wherein the heating element comprises stainless steel.

[0207] Example 75: A heater assembly according to any one of Examples 65-74, wherein the heating element comprises a ferrimagnetic or ferromagnetic material.

[0208] Example 76: A heater assembly according to any one of Examples 65-75, wherein the heating element is coated with a corrosion-resistant material.

[0209] Example 77: A heater assembly according to any one of Examples 65-76, wherein the heating element is coated with a ceramic material.

[0210] Example 78: A heater assembly according to any one of Examples 65 to 77, wherein the support element is configured to absorb heat generated by the heating element.

[0211] Example 79: A heater assembly according to any one of Examples 65-78, wherein the support element comprises at least one of aluminum, copper, brass, gold, silver, or a thermally conductive ceramic.

[0212] Example 80: A heater assembly according to any one of Examples 65 to 79, wherein the thermal conductivity of the support element is at least 10 W / mK.

[0213] Example 81: A heater assembly according to any one of Examples 65 to 80, wherein the thermal conductivity of the support element is at least 50 W / mK.

[0214] Example 82: A heater assembly according to any one of Examples 65 to 81, wherein the thermal conductivity of the support element is at least 200 W / mK.

[0215] Example 83: A heater assembly according to any one of Examples 65 to 82, wherein the support element comprises at least one support pin.

[0216] Example 84: The heater assembly according to example 83, wherein the heating element is engaged with at least one support pin.

[0217] Example 85: A heater assembly according to example 83 or 84, wherein at least one support pin is cylindrical.

[0218] Example 86: A heater assembly according to 85, wherein at least one support pin has a diameter of 0.5 millimeters to 5 millimeters, preferably 1 to 2 millimeters.

[0219] Example 87: A heater assembly according to any one of Examples 65 to 86, wherein the heater holder comprises an upper plate and a lower plate.

[0220] Example 88: A heater assembly according to Example 87, wherein the heating element is located between the upper and lower plates.

[0221] Example 89: A heater assembly according to example 87 or 88, wherein an opening is defined through the upper plate and the lower plate.

[0222] Example 90: A heater assembly according to any one of Examples 65 to 89, wherein the first electrical connector and the second electrical connector are configured to supply power to the heating element and to cause the heating element to be resistively heated.

[0223] Example 91: A heater assembly according to any one of Examples 65 to 90, wherein the support element is positioned adjacent to the opening.

[0224] Example 92: A heater assembly according to any one of Examples 65-91, wherein the electrical connector is placed in thermal contact with the heating element at a distance away from the opening that is greater than the distance from the opening to the support element.

[0225] Example 93: A heater assembly described in any one of Examples 65 to 90, wherein the first electrical connector and the second electrical connector are adjacent to the opening.

[0226] Example 94: The heater assembly according to example 93, wherein the support element contacts the heating element at a distance away from the opening that is greater than the distance from the opening of the first electrical connector and the second electrical connector.

[0227] Example 95: A heater assembly according to any one of Examples 65 to 94, wherein the cross-sectional area of ​​the opening is between 4 square millimeters and 1000 square millimeters.

[0228] Example 96: A heater assembly according to Example 95, wherein the cross-sectional area of ​​the opening is between 9 square millimeters and 400 square millimeters.

[0229] Example 97: A heater assembly according to Example 96, wherein the cross-sectional area of ​​the opening is between 16 square millimeters and 100 square millimeters.

[0230] Example 98: A heater assembly according to any one of Examples 65 to 97, wherein the heater holder is electrically insulating.

[0231] Example 99: A heater assembly according to any one of Examples 65 to 98, wherein the heater holder has a thermal conductivity of 1 W / mk or less.

[0232] Example 100: A heater assembly according to any one of Examples 65 to 99, wherein the heater holder comprises a heat resistant polymer.

[0233] Example 101: A heater assembly according to any one of Examples 65 to 100, wherein the heater holder comprises PEEK.

[0234] Example 102: The heater assembly according to any one of Examples 65-101, wherein the heater holder comprises an LCP.

[0235] Example 103: A heater assembly according to any one of Examples 65 to 102, wherein the heater holder comprises ceramic.

[0236] Example 104: A heater assembly according to any one of Examples 65 to 103, wherein the heater holder comprises alumina.

[0237] Example 105: A heater assembly according to any one of Examples 65-104, wherein the heater holder comprises zirconia.

[0238] Example 106: A heater assembly according to any one of examples 65 to 105, wherein the heater assembly is configured to heat a fluid aerosol-forming substrate.

[0239] Example 107: A heater assembly according to any one of examples 65 to 106, wherein the heater assembly is configured to heat a liquid aerosol-forming substrate.

[0240] Example 108: A heater assembly according to any one of examples 65 to 107, further comprising a compressible element, the compressible element configured to be compressed when the heater assembly receives the aerosol-forming substrate supply.

[0241] Example 109: A heater assembly according to example 108, wherein the compressible element is a spring.

[0242] Example 110: A heater assembly according to example 108, wherein the compressible element is a compressible wicking element.

[0243] Example 111: A cartridge configured to couple with an aerosol generating device as defined in any of Examples 1 to 64, A cartridge comprising an aerosol-forming substrate and a wicking material in fluid communication with the aerosol-forming substrate, the wicking material forming part of an exterior surface of the cartridge and configured to be in contact with an aerosol generating device.

[0244] Example 112: A cartridge according to Example 111, comprising a cartridge airflow passage defined between the cartridge air inlet and the cartridge air outlet.

[0245] Example 113: A cartridge according to example 112, comprising a mouthpiece, the mouthpiece comprising a cartridge air outlet.

[0246] Example 114: A cartridge according to any of Examples 111 to 113, further comprising a removable seal covering the wicking material, the removable seal configured to be removed by a user.

[0247] Example 114a: An aerosol generating system comprising: An aerosol generating device according to any one of Examples EX1 to EX64; A cartridge comprising: An aerosol generating system comprising: a cartridge comprising an aerosol-forming substrate in fluid communication with a wicking material, the wicking material forming part of an exterior surface of the cartridge.

[0248] Example 115: An aerosol generating system comprising: A cartridge comprising: a cartridge comprising an aerosol-forming substrate in fluid communication with a wicking material, the wicking material forming part of an exterior surface of the cartridge; An aerosol generating device, comprising: a cartridge connecting portion for engaging a cartridge comprising an aerosol-forming substrate; an airflow passage defined between the device air inlet and the device air outlet; an aerosol generation system comprising: an aerosol generation device comprising: a heater assembly comprising a fluid-permeable heating element configured to heat an aerosol-forming substrate from a cartridge, the heater assembly having a first side and a second side, the first side facing opposite the second side, the first side forming at least a portion of a surface of a wall of an airflow passage, and the second side forming a portion of a cartridge connecting portion and configured to contact a wicking material of the cartridge to receive the aerosol-forming substrate.

[0249] Example 116: An aerosol generation system according to Example 115, wherein the cartridge comprises a cartridge air inlet and a cartridge air outlet, the cartridge air inlet being aligned with the device air outlet.

[0250] Example 117: An aerosol generating system according to Example 116, further comprising a mouthpiece, the mouthpiece comprising a cartridge air outlet.

[0251] Example 118: An aerosol generating system according to Example 117, wherein the system is smoke-activated.

[0252] Example 119: Aerosol generation according to example 118, wherein the aerosol-forming substrate is a fluid.

[0253] Example 120: An aerosol generating system according to any one of Examples 115 to 119, wherein the device air inlet is defined within a side wall of the aerosol generating device.

[0254] Example 121: An aerosol generation system according to Example 120, wherein the device air outlet is defined in an end wall of the aerosol generation device.

[0255] Example 122: An aerosol generating system according to example 121, wherein the side wall of the aerosol generating device extends perpendicular to the end wall of the aerosol generating device.

[0256] Example 123: An aerosol generating system according to any one of Examples 115 to 122, wherein the second side of the heater assembly is positioned outside the airflow passage.

[0257] Example 124: An aerosol generation system according to any one of Examples 115 to 123, wherein the device air outlet is configured to align with an opening in the cartridge.

[0258] Example 125: An aerosol generating system according to any one of Examples 115 to 124, wherein the heating assembly is a planar heater assembly.

[0259] Example 126: An aerosol generating system according to any one of Examples 115 to 125, wherein the heating element is a planar heating element.

[0260] Example 127: An aerosol generating system according to Example 126, wherein the heating element is perpendicular to the longitudinal axis of the aerosol generating device.

[0261] Example 128: An aerosol generating system according to any one of Examples 115 to 127, wherein the heating element is provided with a mesh.

[0262] Example 129: An aerosol generating system according to any one of Examples 115 to 128, wherein the heating element comprises a porous material.

[0263] Example 130: An aerosol generating system according to any one of Examples 115 to 129, wherein the heating element comprises at least one filament.

[0264] Example 131: An aerosol generating system according to example 130, wherein at least one filament has a diameter of 0.1 millimeters to 0.5 millimeters.

[0265] Example 132: An aerosol generating system according to Example 130, wherein at least one filament has a diameter of 0.02 millimeters to 0.2 millimeters.

[0266] Example 133: An aerosol generating system according to any one of Examples 115 to EX132, wherein the total electrical resistance of the heating element is 0.1 ohms to 5 ohms, preferably 0.4 ohms to 2 ohms.

[0267] Example 134: An aerosol generating system according to any one of Examples 115 to 133, wherein the heating element comprises stainless steel.

[0268] Example 135: An aerosol generating system according to any one of Examples 115 to 134, wherein the heating element comprises a ferrimagnetic or ferromagnetic material.

[0269] Example 136: An aerosol generating system according to any one of Examples 115 to 135, wherein the heating element is coated with a corrosion-resistant material.

[0270] Example 137: An aerosol generating system according to any one of Examples 115 to 136, wherein the heating element is coated with a ceramic material.

[0271] Example 138: An aerosol generating system according to any one of Examples 115 to 137, wherein the heater assembly is configured to contact a wicking portion within the cartridge.

[0272] Example 139: An aerosol generating system according to any one of Examples 115 to 138, wherein the heater assembly comprises a support element, the support element comprising a thermally conductive material in thermal contact with the heating element.

[0273] Example 140: An aerosol generating system according to Example 139, wherein the support element is configured to absorb heat generated by the heating element.

[0274] Example 141: An aerosol generating system according to example 139 or 140, wherein the support element comprises at least one of aluminum, copper, brass, gold, silver, or a thermally conductive ceramic.

[0275] Example 142: An aerosol generating system according to any of Examples 139 to 141, wherein the thermal conductivity of the support element is at least 10 W / mK.

[0276] Example 143: An aerosol generating system according to Example 142, wherein the thermal conductivity of the support element is at least 50 W / mK.

[0277] Example 144: An aerosol generating system according to Example 143, wherein the thermal conductivity of the support element is at least 200 W / mK.

[0278] Example 145: An aerosol generating system according to any of Examples 139 to 144, wherein the support element comprises at least one support pin.

[0279] Example 146: An aerosol generating system according to Example 145, wherein the heating element is engaged with at least one support pin.

[0280] Example 147: An aerosol generating system according to example 139 or 146, wherein at least one support pin is cylindrical.

[0281] Example 148: An aerosol generating system according to example 147, wherein at least one support pin has a diameter of 0.5 millimeters to 5 millimeters, preferably 1 to 2 millimeters.

[0282] Example 149: An aerosol generating system according to any one of Examples 115 to 148, wherein the heater assembly further comprises a heater holder.

[0283] Example 150: An aerosol generating system according to Example 149, wherein the heater holder comprises an upper plate and a lower plate.

[0284] Example 151: An aerosol generating system according to Example 150, wherein a heating element is placed between the upper plate and the lower plate.

[0285] Example 152: An aerosol generating system according to any of Examples 149 to 151, wherein the heater holder has an opening defined therethrough.

[0286] Example 153: An aerosol generating system according to Example 152, wherein an aperture is defined through the upper plate and the lower plate.

[0287] Example 154: An aerosol generating system according to example 152 or 153, wherein a heating element spans at least a portion of the opening.

[0288] Example 155: An aerosol generating system according to any of Examples 152-154, wherein the support element is positioned adjacent to the opening.

[0289] Example 156: An aerosol generation system according to any one of Examples 115 to 155, comprising a first electrical connector and a second electrical connector, the first electrical connector and the second electrical connector configured to supply power to a heating element, and the heating element configured to be resistively heated.

[0290] Example 157: An aerosol generating system according to example 156, wherein the electrical connector is placed in thermal contact with the heating element at a distance away from the opening that is greater than the distance from the opening to the support element.

[0291] Example 158: An aerosol generating system according to Examples 156-157, wherein the first electrical connector and the second electrical connector are positioned adjacent to the opening.

[0292] Example 159: An aerosol generating system according to example 158, wherein the support element contacts the heating element at a distance farther from the opening than the distance from the opening of the first electrical connector and the second electrical connector.

[0293] Example 160: An aerosol generating system according to any of 152 to 159, wherein the cross-sectional area of ​​the opening is between 4 square millimeters and 1000 square millimeters.

[0294] Example 161: An aerosol generating system according to Example 160, wherein the cross-sectional area of ​​the opening is between 9 square millimeters and 400 square millimeters.

[0295] Example 162: An aerosol generating system according to Example 161, wherein the cross-sectional area of ​​the opening is between 16 square millimeters and 100 square millimeters.

[0296] Example 163: An aerosol generating system according to any of Examples 149 to 162, wherein the heater holder is electrically insulating.

[0297] Example 164: An aerosol generating system according to Example 163, wherein the heater holder has a thermal conductivity of 1 W / mk or less.

[0298] Example 165: An aerosol generating system according to Example 163 or 164, wherein the heater holder comprises a heat-resistant polymer.

[0299] Example 166: An aerosol generating system according to any of Examples 163 to 165, wherein the heater holder comprises PEEK.

[0300] Example 167: An aerosol generating system according to any of Examples 163 to 166, wherein the heater holder comprises an LCP.

[0301] Example 168: An aerosol generating system according to any of Examples 163 to 167, wherein the heater holder comprises ceramic.

[0302] Example 169: An aerosol generating system according to Example 168, wherein the heater holder comprises alumina.

[0303] Example 170: An aerosol generating system according to example 168 or 169, wherein the heater holder comprises zirconia.

[0304] Example 171: An aerosol generating system according to any one of Examples 115 to 170, wherein the heater assembly includes a wicking material.

[0305] Example 172: An aerosol generating system according to any one of Examples 115 to 171, wherein the heating element comprises a susceptor material configured to be inductively heated.

[0306] Example 173: An aerosol generating system according to any one of Examples 115 to 172, further comprising a power source.

[0307] Example 174: An aerosol generating system according to any one of Examples 115 to 173, further comprising a control circuit.

[0308] Example 175: An aerosol generating system according to any one of Examples 115 to 175, wherein the aerosol generating system is a handheld aerosol generating system.

[0309] Example 176: An aerosol generating system according to any one of Examples 115 to 175, wherein the heating element is airflow-activated.

[0310] Example 177: An aerosol generating system according to any one of Examples 115 to 176, wherein the heating element is smoke-activated.

[0311] Example 178: An aerosol generating system according to any one of Examples 115 to 177, wherein the heating element is configured to heat the liquid aerosol-forming substrate.

[0312] Example 179: An aerosol generating system according to any one of Examples 115 to 178, wherein the heater assembly comprises a compressible element, the compressible element being configured to be compressed by the cartridge when the cartridge is received by the aerosol generating device.

[0313] Example 180: An aerosol generating system according to Example 179, wherein the compressible element is a spring.

[0314] Example 181: An aerosol generating system according to Example 179, wherein the compressible element is a compressible wicking element disposed on the second side of the heater assembly.

[0315] Features of one aspect of the invention may also be applied to other aspects of the invention.

[0316] The embodiments will now be further described with reference to the figures. [Brief description of the drawings]

[0317] [Figure 1] FIG. 1 shows a simplified cross-sectional view of an aerosol generation system. [Figure 2A-2B] 2A and 2B show exploded and cross-sectional perspective views of a portion of an aerosol generation system. [Figure 3A-3B] Figure 3A shows an exploded perspective view of a heater assembly according to a first embodiment, and Figure 3B shows a perspective view of the heater assembly of Figure 3A. [Figure 4A-4B] Figure 4A shows an exploded perspective view of a heater assembly according to a second embodiment, and Figure 4B shows a perspective view of the heater assembly of Figure 4A. [Diagram 5] FIG. 5 shows a cross-sectional perspective view of the cartridge according to the first embodiment. [Figure 6A-6B] Figure 6A shows a cross-sectional perspective view of a cartridge according to a second embodiment, and Figure 6B shows a perspective view of the cartridge of Figure 6A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0318] 1 shows a cross-sectional diagram of an aerosol generation system 700 comprising an aerosol generating device 500 and a cartridge 600. In this embodiment, the aerosol generation system 700 is an electrically operated smoking system, often referred to as an e-cigarette system. The aerosol generation system 700 is a handheld, portable system and has a size comparable to a traditional cigar or cigarette.

[0319] The device 500 includes a battery 560 , such as a lithium iron phosphate battery, and a controller 570 electrically connected to the battery 560 .

[0320] The device 500 comprises an air inlet 510, an air outlet 520, and a heater assembly 530. An airflow passage is defined between the air inlet 510 and the air outlet 520. The heater assembly 530 is positioned downstream of the air inlet 510 and upstream of the air outlet 520. The heater assembly 530 comprises a fluid permeable heating element 540, first and second electrical connectors (not shown in FIG. 1), a heater holder 550, and a support element (not shown in FIG. 1). The heating element 540 is a heating wire that spans an opening in the heater holder 550. The first and second electrical connectors are electrically connected to the heating element 540, a battery 560, and a controller 570. The device 500 also comprises a compressible element 580, such as a spring.

[0321] The device 500 includes a cartridge coupling portion 502 for engaging a cartridge 600 .

[0322] Cartridge 600 comprises a liquid aerosol-forming substrate in a reservoir 610. In this system, the reservoir 610 is in fluid communication with a ceramic wicking material 620 such that the liquid aerosol-forming substrate can flow from the reservoir 610 to the wicking material 620.

[0323] The cartridge 600 is coupled to the device 500 by a cartridge interface.

[0324] The device air outlet 520 is configured to align with the cartridge air inlet 630. When the device 500 is coupled to the cartridge 600, the device airflow passage is connected to the cartridge airflow passage, defining an airflow passage from the device air inlet 510 to the cartridge air outlet 640. The cartridge includes a mouthpiece, and the cartridge air outlet 640 is defined within the mouthpiece.

[0325] The wicking material 620 is configured to align with the opening in the heater holder 550. The opening is circular in shape with a cross-sectional area between 4 square millimeters and 1000 square millimeters. The wicking material 620 also has a circular cross-section, so that the wicking material 620 may be easily received by the opening in the heater holder 550.

[0326] In use, a user puffs on the mouthpiece of the cartridge 600, drawing air into the device air inlet 510. The system is puff-activated, meaning that a puff sensor (not shown), which may be a pressure sensor or airflow sensor, is located within the system 700. The puff sensor will detect a user puff and send a signal to the controller 570, which results in power being provided from the battery 560 to the heating element 540 via the first electrical connector and the second electrical connector. This causes a current to flow through the heating element 540, thereby resistively heating the heating element 540. In other embodiments, the aerosol generation system may include a button that the user presses to send a signal to the controller to provide power from the battery to the heating element 540.

[0327] When the heating element 540 is resistively heated, where the heating element 540 contacts the support element, the support element conducts heat away from the heating element 540. This minimizes the number of hot spots that occur across the heating element 540, leading to a relatively uniform temperature across the heating element. As the heating element 540 heats, it heats the wicking material 620, and thus any aerosol-forming substrate contained within the wicking material 620. The heating of the wicking material 620 vaporizes the aerosol-forming substrate.

[0328] As the user puffs on the cartridge air outlet 640, air is drawn into the device air inlet 510. As the air is drawn through the air passageway, it passes across the heater assembly 530. The air flows across a first side of the heating element 540, across the surface of the wicking material, and toward the cartridge air outlet. Vaporized aerosol-forming substrate is entrained in the flowing air. The entrained vapor then cools and condenses to form an aerosol. The aerosol leaves the device airflow passageway through the air outlet 520. The aerosol then enters the cartridge 600 through the cartridge air inlet 630, exits the cartridge through the cartridge air outlet 640, and is delivered to the user's mouth.

[0329] As the liquid aerosol-forming substrate in the wicking material 620 is heated, vaporized, and entrained in the airflow, the liquid aerosol-forming substrate from the reservoir 610 advances into the wicking material 620. This aerosol-forming substrate from the reservoir 610 effectively replaces the vaporized aerosol-forming substrate. The liquid aerosol-forming substrate from the reservoir 610 may be drawn into the wicking material 620 at least in part by capillary action. This is because the wicking material 620 is a capillary material having a fibrous or spongy structure.

[0330] After numerous uses of the aerosol generation system 700, the wicking material may begin to degrade. The user can then disconnect the cartridge 600 from the device 500. The cartridge 500 can be removed and discarded. The aerosol generation device 500 can then be reused with a new cartridge.

[0331] 2A shows a perspective view of a portion of an aerosol generation system 800. The system 800 comprises a cartridge 1000 and an aerosol generation device 900. The aerosol generation device 900 comprises a heater assembly. The heater assembly comprises a heater holder comprising an upper plate 952 and a lower plate 954, a heating element 940, and a support pin 962. A device air inlet 910 is defined in a sidewall of the aerosol generation device. A device air outlet 920 is formed in the cartridge interface portion of the device.

[0332] 2B shows a cross-sectional view of the aerosol generation system 800 of FIG. 2A when an aerosol generation device 900 is coupled to a cartridge 1000. The cartridge 1000 is received by a cartridge coupling portion of the device 900.

[0333] 3A shows an exploded view of a heater assembly 130 according to a first embodiment. The heater assembly 130 includes a fluid permeable heating element 140, a heater holder 150, and a support element 160. The heater assembly 130 includes a first side 132 and a second side 134, where the first side 132 faces opposite the second side 134.

[0334] The heater holder 150 comprises an upper plate 152 and a lower plate 154 between which the heating element 140 is placed. Both the upper plate 152 and the lower plate 154 comprise an aperture. When assembled, the aperture in the upper plate 152 and the aperture in the lower plate 154 are aligned, thereby forming an aperture through the heater assembly 130. The cross-sectional area of ​​the aperture is between 9 square millimeters and 400 square millimeters, preferably between 16 square millimeters and 100 square millimeters. The heater holder 150 comprises a high temperature resistant polymer, specifically PEEK or LCP. In other embodiments, the heater holder may comprise a ceramic, such as alumina or zirconia.

[0335] A heating element 140 spans at least a portion of the opening. The heating element is a stainless steel filament (heating wire) configured to be resistively heated. In other embodiments, the heating element may comprise a mesh. The mesh may comprise multiple filaments. The heating element may be coated with a corrosion resistant material, for example a ceramic material. In the embodiment shown in FIG. 3A, the heating wire 140 has a diameter of 0.1 millimeters to 0.5 millimeters. The heating element has a total electrical resistance of 0.1 to 5 ohms, preferably 0.4 to 2 ohms.

[0336] The support element 160 includes six support pins 162. The support pins include a thermally conductive material, such as aluminum, copper, brass, gold-plated metal, silver-plated metal, or a thermally conductive ceramic. The thermal conductivity of the support pins is at least 10 W / mK, preferably at least 50 W / mK, and more preferably at least 200 W / mK. The support pins 162 provide mechanical support to the heating element 140. The support pins 162 also function as thermal conductors to conduct heat away from the heating element 140, specifically, to conduct heat away from hot spots within the heating element 140. The support pins 162 are positioned adjacent to openings in the upper plate 152 and the lower plate 154.

[0337] The heating assembly further comprises a first electrical connector 170 and a second electrical connector 180. The first electrical connector is in electrical contact with a first end of the heating element. The second electrical connector is in electrical contact with a second end of the heating element. The first electrical connector and the second electrical connector are configured to supply electrical power to the heating element 140.

[0338] Figure 3B shows the heater assembly of Figure 3A when assembled. As shown in Figure 3B, an upper plate 152 and a lower plate 154 are attached to form a planar heating assembly.

[0339] The heater assembly 130 is configured such that, in use, electrical power is supplied to the heating element 140 via the first electrical connector 170 and the second electrical connector 180. The electrical power resistively heats the heating element 140. When the heating element 140 is in physical contact with the support pin 162, the support pin 162 conducts heat away from the heating element. Thus, temperature peaks or hot spots within the heating element are reduced. A substantially uniform temperature is achieved across the heating element.

[0340] The heater assembly 130 is fabricated by pressing or gluing a support pin 162 onto the lower plate 154. The heating element (wire) 140 is wrapped around the support pin 162 and held under tension to form the heating net shown in Figures 1A and 1B. A first electrical connector 170 is applied onto a first end of the heating element 140 and a second electrical connector 180 is applied onto a second end of the heating element 140. The upper plate 152 is then applied onto the top of the other element. The upper and lower plates 152 and 154 may be attached by plastic welding the upper and lower plates 152 and 154 together. Alternatively, they may be joined by applying an adhesive between the upper and lower plates 152 and 154. Alternatively or additionally, by adding fasteners such as screws or rivets between the upper and lower plates 152 and 154.

[0341] 4A and 4B show a heater assembly 230 according to a second embodiment of the present disclosure. The heater assembly 230 includes a fluid permeable heating element 240, a heater holder 250, and a support element 260. The heater assembly 230 includes a first side 232 and a second side 234, where the first side 232 faces opposite the second side 234.

[0342] The embodiment shown in FIG. 4A shows a first electrical connector 270 and a second electrical connector 280 adjacent to an opening in the upper plate and an opening in the lower plate. The support element 260 includes a support pin 262. In this embodiment, the support pin 262 is located at a greater distance from the opening than the distance of the electrical connectors from the opening. The first electrical connector 270 and the second electrical connector 280 are located adjacent to the opening and the heating element 240 spans the opening. The heating element is a heating wire having a diameter of 0.02 mm to 0.2 mm and is wrapped around the support pin 262. The first electrical connector 270 and the second electrical connector 280 are applied to either side of the heating wire and connected in parallel.

[0343] FIG. 4B shows the heater assembly of FIG. 4A when assembled. During use of the heater assembly 230, power is supplied to the heating element 240 via the first electrical connector 270 and the second electrical connector 280. The power delivers an electrical current to the heating element 240, which is configured to be resistively heated. When the heating element 240 is in physical contact with the support pin 262, the support pin 262 conducts heat away from the heating element. Thus, temperature peaks or hot spots within the heating element are reduced. In this configuration, the electrical current flows along the portion of the heating wire between the first electrical connector 270 and the second electrical connector 280. Due to the location of the first electrical connector 270 and the second electrical connector 280, the electrical current does not flow to the portion of the heating element that is in contact with the support pin 262. In this embodiment, the first electrical connector 270 and the second electrical connector 280 act to conduct heat away from the heating element 240 and reduce hot spots within the heating element 240. Specifically, the connector conducts heat away from the portions of the heating element 230 with which it is in physical contact, in this case the portions that are also in contact with the heater holder 250, and therefore areas where hot spots are more likely to occur.

[0344] FIG. 5 shows a cartridge 300. The cartridge 300 comprises an aerosol-forming substrate stored in a reservoir 310 and a wicking material 320 in fluid communication with the aerosol-forming substrate. The reservoir 310 may be of any size or shape suitable for accommodating the aerosol-forming substrate in the cartridge 300. In this embodiment, the aerosol-forming substrate is a liquid. A portion of the reservoir 310 contacts the wicking material 320. This portion is configured to allow fluid to pass between the reservoir 310 and the wicking material 320. This portion of the reservoir 310 has an opening 350 defined therethrough to allow fluid to pass therethrough. During use of the system, the fluid aerosol-forming substrate can flow from the reservoir to the wicking material, and gas, such as air, can flow through the wicking material to the reservoir to allow pressure to balance in the system.

[0345] The wicking material 320 is a porous ceramic and forms part of the exterior surface of the cartridge 300 and is configured to contact the aerosol-generating device. The wicking material is configured to absorb and transport the fluid aerosol-forming substrate through the wicking material.

[0346] The cartridge 300 also includes a cartridge air inlet 330 and a cartridge air outlet 340. A cartridge airflow passage is defined between the cartridge air inlet 330 and the cartridge air outlet 340. The cartridge further includes a mouthpiece 360. The mouthpiece includes a cartridge air outlet. In use, when the cartridge is engaged with an aerosol generating device, a user may puff on the mouthpiece of the cartridge to draw air through the system and out the cartridge air outlet.

[0347] 6A and 6B show a second embodiment of a cartridge 400 with a removable seal. A wicking material 420 forms part of the exterior surface of the cartridge 400 and is configured to contact an aerosol generating device. The cartridge 400 includes a protruding wall 470 that surrounds the periphery of the device interface portion of the cartridge 400. The protruding wall 470 protrudes further from the cartridge than the wicking material 420. The cartridge air inlet 430 includes a separation wall 480 that protrudes from the surface of the device interface portion.

[0348] The cartridge 400 includes a removable seal 460 attached to a separation wall 480 and a protruding wall 470 of the cartridge.

[0349] The removable seal is configured to be removed by a user prior to coupling of the cartridge 400 with an instrument.

[0350] Figure 6B shows the cartridge of Figure 6A with the removable seal 460 peeled away from the cartridge 400. Figure 6B shows the removable seal 460 partially removed from the cartridge.

[0351] For 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±10%. Within this context, the number A may be considered to include a numerical value that is within the typical standard error for the measurement of the property that the number A modifies. The number A may, in some instances used in the appended claims, deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel properties of the claimed invention. Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. An aerosol generating device for connection to a cartridge, comprising: a cartridge connecting portion for engaging a cartridge containing an aerosol-forming substrate; an airflow passage defined between the air inlet and the air outlet; a heater assembly comprising a fluid-permeable heating element configured to heat an aerosol-forming substrate from the cartridge, the heater assembly having a first side and a second side, the first side facing opposite the second side, the first side forming at least a part of a surface of a wall of the airflow passage and the second side forming a part of the cartridge interface and configured to contact the cartridge and receive the aerosol-forming substrate; The heater assembly comprises a support element, the support element comprising a thermally conductive material in thermal contact with the heating element.

2. 2. The aerosol generating device of claim 1, wherein the support element comprises at least one of aluminum, copper, brass, gold, silver, or a thermally conductive ceramic.

3. 3. The aerosol generating device of claim 1, wherein the heater assembly further comprises a heater holder comprising a heat resistant polymer.

4. 4. The aerosol generating device of claim 3, wherein the heater holder has an opening defined therethrough.

5. 5. The aerosol generating device of claim 4, wherein the heater holder comprises an upper plate and a lower plate, and the opening is defined through the upper plate and the lower plate.

6. 6. The aerosol generating device according to claim 4 or 5, wherein the heating element spans at least a portion of the opening.

7. 6. The aerosol generating device according to claim 1, wherein the heating element is a heating wire having a diameter of 0.1 millimeters to 0.5 millimeters, or a diameter of 0.02 millimeters to 0.2 millimeters.

8. An aerosol generating device as described in any one of claims 1 to 7, further comprising a first electrical connector and a second electrical connector, the first electrical connector and the second electrical connector configured to supply power to the heating element and configured to resistively heat the heating element.

9. The aerosol generating device of claim 8 , wherein the first electrical connector and the second electrical connector are positioned adjacent to the opening.

10. 9. An aerosol generating device according to any preceding claim, wherein the support element is positioned adjacent to the opening.

11. 1. A heater assembly for an aerosol generating device, comprising: a heater holder having an opening; a heating element spanning at least a portion of the opening; a first electrical connector and a second electrical connector in electrical contact with the heating element; a support element comprising a thermally conductive material in thermal contact with the heating element.

12. 1. An aerosol generation system comprising: An aerosol generating device according to any one of claims 1 to 10, A cartridge comprising:

1. An aerosol generating system comprising: a cartridge comprising an aerosol-forming substrate in fluid communication with a wicking material, the wicking material forming part of an exterior surface of the cartridge.

13. 13. The aerosol generation system of claim 12, further comprising a compressible element, the compressible element configured to be compressed by the cartridge when the cartridge is received by the aerosol generation device.

14. 14. The aerosol generation system of claim 12 or 13, further comprising a mouthpiece and a cartridge airflow passage defined between a cartridge air inlet and a cartridge air outlet, the cartridge air inlet being aligned with the device air outlet and the mouthpiece comprising the cartridge air outlet.

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