Heater assembly for improved robustness of aerosol generators

Abstract

A heater assembly (400) for an aerosol generating device. The heater assembly (400) comprises a heating element (430). The heating element (430) comprises a plurality of heating sections (431) and at least one mounting section (432). The heating element (430) comprises a support structure (460) having a support structure opening (461) and an upper support structure surface (462) parallel to a first plane. The heater assembly (400) comprises a frame (420). The frame (420) at least partially surrounds the support structure (460). The heater assembly (400) comprises a first electrical contact (491) in electrical contact with a first end of the heating element (430). The heater assembly (400) comprises a second electrical contact (492) in electrical contact with a second end of the heating element (430). The heating elements (430) provide a continuous electrical path between the first electrical contact (491) and the second electrical contact (492). The heating elements (430) are fixed to the frame (420). Each heating section (431) is located within or over a support structure opening (461) and is separated from the frame by at least one mounting section (432). Each mounting section includes a first section (433) and a second section (434). Each first section (433) is substantially parallel to a first plane. Each second section (434) extends from the upper support structure surface (462) toward a second plane that is parallel to, but not coplanar with, the upper support structure surface (462).

Description

[Technical Field]

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

[0002] Aerosol generation systems configured to generate inhalable aerosols from aerosol-forming substrates are known in the art. Some conventional aerosol generation systems include an aerosol generating device that can be coupled to a cartridge. A typical cartridge for use in an aerosol generating device includes an aerosol-forming substrate and a heater assembly, where the heater assembly includes a heating element. In many cases, the aerosol-forming substrate is liquid. In this case, the cartridge may further include a wicking material in fluid communication with the aerosol-forming substrate and in contact with the heating element. The wicking material is configured to transport the liquid aerosol-forming substrate to the heating element. In use, the heating element is configured to vaporize the liquid aerosol-forming substrate. For example, the heating element may be resistively heated. An airflow is provided past the heating element to entrain the generated vapor. The vapor condenses within the airflow, and an aerosol is formed. The aerosol may then be inhaled by a user. An aerosol generating device typically includes a power source configured to provide power to the heating element when the device and cartridge are connected via an electrical connector.

[0003] In this type of aerosol generation system, the heating element is fixed to the heater assembly, aerosol generator, cartridge, or other component of the aerosol generation system, depending on the location of the heating element. This provides stability to the heating element and minimizes damage to the heating element during use. However, as the heating element becomes hot during use, heat can be transferred from the heating element to the heater assembly, aerosol generator, cartridge, or other component of the aerosol generation system. This heat transfer can damage these other components. Furthermore, this heat transfer can cause the aerosol generator, cartridge, or other component of the aerosol generation system to become hot to the touch during use, which can negatively impact the user's overall experience.

[0004] It would therefore be desirable to provide heater assemblies, aerosol generators, cartridges, and aerosol generation systems that minimize heat transfer between the heating element and other components of the heater assembly, aerosol generator, cartridge, or aerosol generation system during use.

[0005] When a heating element is coupled to a wicking material, reliable physical contact between the heating element and the wicking material is beneficial for reliable aerosol generation. Therefore, the heating element is typically coupled to the wicking material such that the wicking material applies a force to the heating element. Therefore, when a heating element is coupled to a wicking material, it would be beneficial to provide a heater assembly with a robust heating element so that the wicking material does not damage the heating element. Summary of the Invention

[0006] According to a first embodiment of the present disclosure, there is provided a heater assembly for an aerosol generating device. The heater assembly may include a heating element, a first electrical contact in electrical contact with a first end of the heating element, and a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include a plurality of heating sections. The heating element may further include at least one mounting section. The at least one mounting section may be positioned between the heating sections along the continuous electrical path. The heating element may include a frame with openings in a first plane, the heating element being fixed to the frame. Each heating section may be within or above the openings. Each heating section may be separated from the frame by at least one mounting section. The heater assembly may further include a support structure. The frame may at least partially surround the support structure. The support structure may include a support structure opening. The support structure opening may be in the first plane. At least a portion of the heating element may be within the support structure opening. In particular, the plurality of heating elements may be within the support structure opening. At least a portion of the heating element may be above the support structure opening. In particular, the plurality of heating elements may be above the support structure opening. The support structure may include an upper support structure surface parallel to a first plane. Each mounting portion may include a first section and a second section. Each first section may be substantially coplanar with the upper support structure surface. Each second section may extend from the upper support structure surface toward the second plane. The second plane may be parallel to, but not coplanar with, the upper support structure surface.

[0007] Advantageously, this arrangement provides a more robust structure for the heating element. Advantageously, this arrangement also means that the wicking element within the cartridge is configured to contact the heating element, and does not need to protrude from the cartridge, as the heating element is part of the aerosol generating device that couples to the cartridge. Advantageously, this feature also allows for easier transport of the aerosol from the heating element where it is generated to the user.

[0008] The support structure opening may be substantially circular. The support structure opening may be substantially square or rectangular. The support structure opening may be substantially oval in shape. The support structure may comprise a high temperature polymer. For example, the support structure may comprise polyetheretherketone (PEEK). Alternatively, the support structure may comprise a ceramic. For example, the support structure may comprise alumina. In another embodiment, the support structure may comprise zirconia. The support structure may comprise the same material as the frame. Alternatively, the support structure may comprise a different material than the frame. The support structure opening may have a cross-sectional area in the first plane between 1 square millimeter and 1000 square millimeters. The support structure opening may have a cross-sectional area in the first plane between 2 square millimeters and 200 square millimeters. Preferably, the support structure opening has a cross-sectional area in the first plane between 4 square millimeters and 50 square millimeters.

[0009] At least a portion of the heating element may be flush with the upper support structure surface. The plurality of heating sections may be substantially flush with the upper support structure surface. Each second section may extend in a direction perpendicular to the upper support structure surface. Each second section may be disposed between the frame and the support structure. Each second section may be fixed between the frame and the support structure. Advantageously, each second section may be disposed or fixed between the frame and the support structure, thereby providing a heating element that is firmly fixed in place.

[0010] Both the first electrical contact and the second electrical contact may comprise a first electrical contact section and a second electrical contact section. Both first electrical contact sections may be substantially coplanar with the upper support structure surface. Both second electrical contact sections may extend from the upper support structure surface toward the second plane. Both second electrical contact sections may extend in a direction perpendicular to the upper support structure surface. Advantageously, this arrangement may provide a more robust structure for the heating element.

[0011] Both second electrical contact sections may be disposed between the frame and the support structure. Both second electrical contact sections may be fixed between the frame and the support structure. Advantageously, having both second electrical contact sections disposed or fixed between the frame and the support structure can result in a heating element that is firmly fixed in place.

[0012] The frame may include an upper surface that is coplanar with the upper support structure surface. The frame may include a lower frame surface. The support structure may include a lower support structure surface that is coplanar with the lower surface of the frame. Each of the first electrical contact and the second electrical contact may further include a third electrical contact section. Both third electrical contact sections may be substantially coplanar with the lower surface of the frame.

[0013] The plurality of heating elements may be flush with the top surface of the frame.

[0014] The cross-sectional area of each heating portion in a direction perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of each mounting portion in a direction perpendicular to the direction of the continuous electrical path, thereby advantageously reducing heat transfer from the heating element to the frame, and therefore reducing the temperature of the frame during use.

[0015] The plurality of heating portions and the at least one mounting portion may all be integrally formed, which may advantageously simplify manufacturing and increase the robustness of the heating element.

[0016] Each mounting portion may be directly connected to exactly two heating portions. Each heating portion may be directly connected to exactly two mounting portions, or to exactly one mounting portion and either the first electrical contact or the second electrical contact. Such an arrangement can advantageously provide an electrical path that is easy to manufacture, since it ensures that the cross-sectional area of each heating portion in a direction perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of each mounting portion in a direction perpendicular to the direction of the continuous electrical path.

[0017] Each heating portion may have a first width in a first direction and each mounting portion may have a second width in the first direction, the second width being greater than the first width. Advantageously, this provides an arrangement that ensures that the cross-sectional area of each heating portion in a direction perpendicular to the direction of the continuous electrical path can be smaller than the cross-sectional area of each mounting portion in a direction perpendicular to the direction of the continuous electrical path, and is simple to manufacture by common manufacturing methods such as laser cutting, water jet cutting, or chemical etching stamping.

[0018] Each heating element may extend perpendicular to a first direction. The first direction may lie in a first plane. The first direction may be perpendicular to the direction of a continuous electrical path, if the direction of the continuous electrical path is defined by each heating element. The ratio of the first width to the second width may be 1 / 20 to 1 / 2. Preferably, the ratio of the first width to the second width is 1 / 10 to 1 / 4. The first width may be 0.1 mm to 2 mm. Preferably, the first width is 0.2 mm to 1 mm. More preferably, the first width is 0.2 mm to 0.5 mm.

[0019] The heating element may have a thickness in at least one direction perpendicular to the first direction. The thickness may be 0.02 millimeters to 0.5 millimeters. The thickness is preferably 0.05 millimeters to 0.3 millimeters. These dimensions are robust and can advantageously provide a heating element capable of providing sufficient energy to heat the aerosol-forming substrate when the aerosol-generating device is a handheld device.

[0020] The heater assembly may include a gap between adjacent heating sections. The gap may have a gap width. The gap width may be in a first direction. The gap width may be between 0.1 millimeters and 1 millimeter. Preferably, the gap width is between 0.2 millimeters and 0.5 millimeters.

[0021] The plurality of heating sections may comprise between 2 and 20 heating sections. Preferably, the plurality of heating sections comprises between 3 and 9 heating sections. Further, the plurality of heating sections preferably comprises 6 heating sections. Preferably, the plurality of heating sections comprises an even number of heating sections. Advantageously, an even number of heating sections means that the first and second electrical contacts can be located on the same side of the heater assembly.

[0022] The electrical resistance per unit length in the direction of the conductive path of the plurality of heating portions may be greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting portion. The electrical resistance per unit length may be measured by measuring the electrical resistance across each of the heating portions or mounting portions and dividing the electrical resistance by the length of each of the heating portions or mounting portions in the direction of the conductive path. The direction of the conductive path may be curved, for example, if the mounting portions are curved. The electrical resistance of each heating portion may be higher than the electrical resistance of each mounting portion.

[0023] The heater assembly may be configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the plurality of heating sections is greater than the temperature of the at least one attachment section. The heater assembly may be configured such that when a non-zero current is applied through the heating element between the first electrical contact and the second electrical contact, the temperature of the plurality of heating sections is greater than the temperature of the at least one attachment section. In these cases, the temperatures of the plurality of heating sections and the at least one attachment section may be average temperatures over the length of each of the plurality of heating sections of the at least one attachment section.

[0024] The heating element may be serpentine-shaped. The heating element may be serpentine-shaped in the first plane. The heating element may be serpentine-shaped when projected onto the first plane. Advantageously, such an arrangement allows many heating sections to be arranged or packaged in a reduced area. Furthermore, the serpentine arrangement may be fluid-permeable. The heater assembly may include spaces between the heating sections of the heating element. Thus, steam generated by the heating element may pass through the serpentine heating element.

[0025] The heating element may include stainless steel. The heating element may include a ferrimagnetic or ferromagnetic material. Advantageously, the skin depth of the ferrimagnetic or ferromagnetic material decreases when the frequency of the alternating current applied to the heating element increases. The electrical resistance of the heating element increases as a function of frequency. Therefore, the use of ferrimagnetic or ferromagnetic tracks can allow for an increase in its electrical resistance. This allows for more heat to be generated locally without reducing the thickness of the heating element or compromising its mechanical strength.

[0026] The heating element may be coated with a corrosion-resistant material. In particular, the heating element may be coated with a ceramic material. Advantageously, this may extend the life of the heating element and the heater assembly. This is particularly relevant because the heater assembly may be configured to be reversibly coupled to and separated from the wicking element, such that the heater assembly is reusable.

[0027] The heating element may be substantially flat, which may advantageously simplify the manufacture of the heating element.

[0028] The total resistance of the heating element may be between 0.1 ohms and 5 ohms, preferably between 0.2 ohms and 1.5 ohms.

[0029] The heating element and the first and second electrical contacts may be integrally formed. The heating element and the first and second electrical contacts may be formed from the same material. Advantageously, these features may simplify manufacturing of the heating element.

[0030] The opening may be substantially square or rectangular. Alternatively, the opening may be substantially circular. Advantageously, such a shape of the opening may ensure that the wicking element is easily aligned with the opening when the aerosol generating device is coupled to the cartridge. Furthermore, such a shape may make it easy to manufacture the opening or the corresponding wicking element.

[0031] The frame may be electrically insulating. In particular, the frame may have a thermal conductivity of 1 W / mK or less. This may advantageously ensure that the electrical path through the heating element is well defined as a single electrical path, minimizing current flow through the frame and therefore resistive heating of the frame.

[0032] The frame may comprise a high temperature polymer. For example, the frame may comprise polyetheretherketone (PEEK). Alternatively, the frame may comprise a ceramic. For example, the frame may comprise alumina. In another embodiment, the frame may comprise zirconia.

[0033] The frame may be overmolded over a section of the heating element. For example, the frame may be overmolded over a mounting section of at least one mounting portion. Additionally or alternatively, the frame may be overmolded over at least a mounting section of the first electrical contact and at least a section of the second electrical contact. Advantageously, overmolding may provide a robust connection between the frame and the heating element.

[0034] The frame may include an upper element and a lower element. The upper element and the lower element may include press-fit elements such that the upper element and the lower element can be coupled together by a press fit. Alternatively, the upper element and the lower element may include snap-fit elements such that the upper element and the lower element can be coupled together by a snap fit. Alternatively, the upper element and the lower element may include fastening elements such that the upper element and the lower element can be coupled together by fastening. Advantageously, a frame including an upper element and a lower element may provide simplified manufacturing and a modular system in which, for example, the heating element can be replaced. At least a mounting section of the at least one mounting portion may be located between the upper element and the lower element when the upper element and the lower element are coupled together. Additionally or alternatively, at least a mounting section of the first electrical contact and at least a section of the second electrical contact may be located between the upper element and the lower element when the upper element and the lower element are coupled together. Advantageously, such an arrangement ensures that the heating element does not come into contact with the frame.

[0035] The opening may have a cross-sectional area in the first plane of 1 to 1000 square millimeters. The opening preferably has a cross-sectional area in the first plane of 2 to 200 square millimeters. More preferably, the opening has a cross-sectional area in the first plane of 4 to 50 square millimeters.

[0036] The heating element may further comprise at least one thermal insulator. Each mounting portion may be separated from the frame by one thermal insulator. Advantageously, the thermal insulator may further reduce the amount of heat transferred from the plurality of heating portions to the frame via the at least one mounting portion.

[0037] Each heating section may be connected to the frame via at least one thermal insulation section.

[0038] The plurality of heating portions, at least one mounting portion, and at least one insulating portion may all be integrally formed. Advantageously, this simplifies manufacturing as the heating element can be produced by common manufacturing methods such as laser cutting, water jet cutting, or chemical etching stamping.

[0039] Each insulating section does not have to be directly attached to a heating section. There may be an attachment between each insulating section and any heating section. Each insulating section may be located outside of a continuous electrical path. For example, each insulating section may be located outside of a continuous electrical path, and the insulating section experiences a lower temperature rise due to direct resistive heating than both the temperature rise of each attachment section and the temperature rise of each heating section.

[0040] Each insulating section may have a third width in the first direction. The third width may be smaller than the second width. The ratio of the third width to the second width may be between 1 / 10 and 2 / 3. Preferably, the ratio of the third width to the second width is between 1 / 5 and 1 / 3. The third width may be approximately equal to the first width. Advantageously, this simplifies manufacturing while providing an insulating section that reduces the amount of heat transferred from the heating section to the frame.

[0041] The thermal resistance across each attachment between adjacent heating sections and adjacent insulation sections may be lower than the thermal resistance across each insulation section between adjacent attachment sections and the frame. Thermal resistance may be defined as the temperature difference at which an object or material resists heat flow. The thermal resistance (R) across an attachment between adjacent heating sections and adjacent insulation sections may be defined as:

number

[0042] The thermal resistance for each insulation section between adjacent mounting sections and the frame may be defined using the same equation, where x is the length of each insulation section measured in the direction of the heat path between the adjacent mounting section and the frame, A is the cross-sectional area of each insulation section in the direction of the heat path between the adjacent mounting section and the frame, and k is the thermal conductivity of each insulation section, a material constant.

[0043] At least one heating section may have a radius of curvature perpendicular to the first plane. At least one heating section may have a finite radius of curvature perpendicular to the first plane. Each heating section may have a radius of curvature perpendicular to the first plane. At least one heating section may extend convexly with respect to a direction in which the wicking element may be coupled to the heater assembly. At least one heating section may have at least two sections extending in at least two different directions that are not parallel to the first plane. At least one heating section may extend arcuately out of the first plane. At least one heating section may extend out of the first plane in a dome. At least one heating section may curve from the first plane. At least one heating section may extend arcuately out of the first plane. At least one heating section may have a radius of curvature perpendicular to the first plane such that, when the at least one heating section is reversibly deformed by a force to become parallel to the first plane, a reaction force exerted by the at least one heating section is greater at a center of the at least one heating section than at a periphery of the at least one heating section. Advantageously, when the aerosol generating device is coupled to the cartridge such that the heater assembly is coupled to the wicking element, the heating element may exert a greater force at the center of the connecting surface of the wicking element than at the periphery of the connecting surface of the wicking element.

[0044] Each heating section may have the same radius of curvature perpendicular to the first plane. Alternatively, each heating section may have a radius of curvature perpendicular to the first plane selected from a plurality of radii of curvature. For example, each heating section may have a different radius of curvature perpendicular to the first plane.

[0045] The heater assembly may be configured such that when the wicking element is coupled to the heater assembly, the heating element exerts a non-uniform force on the connecting surface of the wicking element, for example, the heating element may exert a greater force at the center of the connecting surface of the wicking element than at the periphery of the connecting surface of the wicking element.

[0046] The heating element may comprise an elastic material, and advantageously, when the aerosol generating device is coupled to the cartridge such that the heater assembly is coupled to the wicking element, the heating element may elastically deform instead of shattering.

[0047] The frame may have an upper surface parallel to the first plane. At least a portion of the heating element may be recessed a first distance from the upper surface of the frame. The first distance may be 0.2 mm to 5 mm. Advantageously, such an arrangement may protect at least a portion of the heating element from damage, particularly when the heating element is uncovered and on an outer surface of the aerosol generating device. A mounting section of at least one mounting portion may be recessed a first distance from the upper surface of the frame.

[0048] At least a second portion of the heating element may coincide with the plane formed by the upper surface of the frame. Advantageously, such an arrangement means that the protrusion required for the wicking element is minimized, and the wicking element is configured to contact the heating element when a cartridge including the wicking element is coupled to an aerosol generating device including the heater assembly. At least a second portion of the heating element may coincide with the plane formed by the upper surface of the frame. At least a second portion of the heating element may extend beyond the plane formed by the upper surface of the frame. A radius of curvature perpendicular to the first plane may be applied to the second portion of the heating element.

[0049] Alternatively, the entire heating element may be recessed a first distance from the top surface of the frame. Advantageously, as noted above, such an arrangement may protect the entire heating element from damage, particularly if the heating element is uncovered and on the exterior surface of the aerosol generating device.

[0050] The frame may have a lower surface parallel to the first plane. At least a first portion of the heating element may be recessed from the lower surface of the frame by a second distance. The second distance may be 0.2 mm to 5 mm.

[0051] The mounting section of the at least one mounting portion may be recessed a second distance from the underside of the frame. Advantageously, such an arrangement may protect at least the at least one mounting portion from damage, particularly during handling of the heater assembly and aerosol generating device assembly.

[0052] According to a second embodiment of the present disclosure, there is provided an aerosol generating device. The aerosol generating device may include a heater assembly. The aerosol generating device may include the heater assembly according to the first embodiment of the present disclosure. The heater assembly may include a heating element. The heater assembly may include a first electrical contact in electrical contact with a first end of the heating element. The heater assembly may include a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include a plurality of heating sections. The heating element may include at least one mounting section disposed between the heating sections along the continuous electrical path. The heater assembly may include a frame. The frame may include openings in the first plane. The heating element may be fixed to the frame. Each heating section may be within the opening. Each heating section may be above the opening. Each heating section may be separated from the frame by at least one mounting section. The heater assembly may further include a support structure. The frame may at least partially surround the support structure. The support structure may include a support structure opening. The support structure opening may be in a first plane. At least a portion of the heating element may be within the support structure opening. In particular, multiple heating elements may be within the support structure opening. At least a portion of the heating element may be above the support structure opening. In particular, multiple heating elements may be above the support structure opening. The support structure may include an upper support structure surface parallel to the first plane. Each mounting portion may include a first section and a second section. Each first section may be substantially parallel to the first plane. Each first section may be substantially coplanar with the upper support structure surface. Each second section may extend from the upper support structure surface toward the second plane. The second plane may be parallel to but not coplanar with the upper support structure surface. Advantageously, this arrangement provides a more robust structure for the heating element. The aerosol generating device may further include an air flow path defined between the air inlet and the air outlet. The air flow path may be in fluid communication with the heating element. In particular, the air flow passage may be in fluid communication with a first side of the heating element.The air flow path may pass through the heater assembly. The heater assembly may include a heater assembly air flow path between a heater assembly air inlet and a heater assembly air outlet. The aerosol generating device may further include a power source. The power source may be in electrical contact with the first electrical contact and the second electrical contact. The power source may be configured to supply power to the heating element. The aerosol generating device may further include control circuitry. The control circuitry may be configured to control the supply of power from the power source to the heating element.

[0053] 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.

[0054] The control circuit may be connected to a power source. The control circuit may be connected to the heating element. The control circuit may control the supply of power from the power source to the heating element. The control circuit may control the temperature of the heating element. The control circuit may comprise a controller. The control circuit may comprise a microcontroller. The microcontroller may be a programmable microcontroller.

[0055] The aerosol generating device may be a handheld aerosol generating device. The aerosol generating device may have a size comparable to that of a conventional cigar or cigarette. The aerosol generating device may have a total length of about 25 mm to about 150 mm. The aerosol generating device may have an outer diameter of about 5 mm to about 30 mm.

[0056] The control circuit may further include a smoke detector in fluid communication with the air flow path. The device may be configured with a heating element to activate the smoke. Advantageously, this may reduce energy consumption from the battery and ensure that aerosol is only generated when desired by the user.

[0057] 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 air outlet may be defined in a proximal end wall of the device. Advantageously, an air outlet defined in the proximal end wall of the device means that a cartridge comprising a mouthpiece can be simply coupled to the proximal end wall and therefore to the air outlet. The side wall of the device may extend perpendicular to the end wall of the device.

[0058] According to a third embodiment of the present disclosure, there is provided an aerosol generation system. The aerosol generation system may comprise a cartridge. The cartridge may comprise an aerosol-forming substrate. The cartridge may comprise a reservoir for containing the aerosol-forming substrate. The aerosol-forming substrate may be in fluid communication with a wicking material. The wicking material may form part of an outer surface of the cartridge.

[0059] The aerosol generating system may comprise an aerosol generating device. The aerosol generating system may comprise an aerosol generating device according to a second embodiment of the present disclosure. The aerosol generating device may comprise a heater assembly. The aerosol generating device may comprise a heater assembly according to a first embodiment of the present disclosure. The heater assembly may comprise a heating element. The heater assembly may further comprise a first electrical contact in electrical contact with a first end of the heating element. The heater assembly may further comprise a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact.

[0060] The heating element may comprise a plurality of heating sections. The heating element may further comprise at least one mounting section. The at least one mounting section may be positioned between the heating sections along the continuous electrical path.

[0061] The heater assembly may include a frame. The frame may include an opening. The frame may include an opening in a first plane.

[0062] The heating elements may be fixed to the frame. Each heating element may be within the opening. Each heating element may be above the opening. Each heating element may be separated from the frame by at least one mounting element. The heater assembly may further comprise a support structure. The frame may at least partially surround the support structure. The support structure may comprise a support structure opening. The support structure opening may be in a first plane. At least a portion of the heating element may be within the support structure opening. In particular, multiple heating elements may be within the support structure opening. At least a portion of the heating element may be above the support structure opening. In particular, multiple heating elements may be above the support structure opening. The support structure may comprise an upper support structure surface parallel to the first plane. Each mounting element may comprise a first section and a second section. Each first section may be substantially parallel to the first plane. Each first section may be substantially coplanar with the upper support structure surface. Each second section may extend from the upper support structure surface toward the second plane. The second plane may be parallel to, but not coplanar with, the upper support structure surface. Advantageously, this arrangement may provide a more robust structure for the heating element. The cross-sectional area of each heating portion in a direction perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of each mounting portion in a direction perpendicular to the direction of the continuous electrical path.

[0063] The aerosol generation system may comprise a system air flow path defined between the system air inlet and the system air outlet. Particularly, as in the second embodiment, the aerosol generation device may further comprise an air flow path defined between the air inlet and the air outlet. The system air flow path may comprise the device air flow path. The system air inlet may comprise the device air inlet. The system air outlet may comprise the device air outlet. The device air flow path may be in fluid communication with the heating element. Particularly, the device air flow path may be in fluid communication with a first side of the heating element. The system air flow path may pass through a heater assembly. Particularly, the device air flow path may pass through the heater assembly. The heater assembly may comprise a heater assembly air flow path between the heater assembly air inlet and the heater assembly air outlet. The device air inlet may comprise a heater assembly air inlet. The system air flow path may comprise a heater assembly air flow path. Particularly, the device air flow path may comprise a heater assembly air flow path.

[0064] The aerosol generating device may further include a power source. The power source may be in electrical contact with the first electrical contact and the second electrical contact. The power source may be configured to supply power to the heating element. The aerosol generating device may further include a control circuit. The control circuit may be configured to control the supply of power from the power source to the heating element. Thus, advantageously, the power supplied to the heating element may be varied based on usage behavior.

[0065] The cartridge may be reversibly connectable to the aerosol generating device. The cartridge may be reversibly connectable to the aerosol generating device such that the wicking material is in direct contact with the heating element when the cartridge is connected to the device. Advantageously, the reversible connectability of the cartridge to the aerosol generating device means that when the cartridge is emptied or damaged, it can be discarded and replaced with a new cartridge. This can have cost savings and environmental benefits, as fewer components are discarded. The wicking element may have a cross-sectional area equal to the cross-sectional area of the opening. The wicking element may have a cross-sectional shape approximately the same as the cross-sectional shape of the opening.

[0066] The air flow path of the aerosol generating device may be in fluid communication with a first side of the heating element. When the cartridge is coupled to the device, the wicking material may be in direct contact with a second side of the heating element. The first side of the heating element may be opposite the second side of the heating element.

[0067] The cartridge may further include a cartridge air flow path defined between the cartridge air inlet and the cartridge air outlet.

[0068] The cartridge may further comprise a removable seal covering a portion of the cartridge. In particular, the cartridge may further comprise a removable seal covering the wicking element. The removable seal may be configured to be removed by a user.

[0069] When the cartridge is coupled to a device, the cartridge air inlet may be in fluid communication with the air outlet of the device.

[0070] The cartridge air outlet may comprise a mouthpiece.

[0071] The aerosol generating system may be a handheld aerosol generating system configured to allow a user to draw on a mouthpiece to draw aerosol through the cartridge air outlet. 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 25 mm to about 150 mm. The aerosol generating system may have an outer diameter of about 5 mm to about 30 mm.

[0072] The aerosol-forming substrate may be a liquid. In particular, the aerosol-forming substrate may be a liquid at standard temperature and pressure. Advantageously, this ensures that the liquid aerosol-forming substrate can be easily transferred from the reservoir to the wicking element and then to the heating element when the system is used at standard temperature and pressure. The aerosol-forming substrate may be a liquid at room temperature. The aerosol-forming substrate may be in another condensed form, such as a solid, at room temperature, or in another condensed form, such as a gel, at room temperature. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may contain both liquid and solid components. The liquid aerosol-forming substrate may contain nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt matrix. The liquid aerosol-forming substrate may contain a plant-derived material. The liquid aerosol-forming substrate may contain tobacco. The liquid aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may comprise a homogenized tobacco material. The liquid aerosol-forming substrate may comprise a non-tobacco-containing material. The liquid aerosol-forming substrate may comprise homogenized plant-derived material.

[0073] The liquid aerosol-forming substrate may contain one or more aerosol formers. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense, stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the system. Examples of suitable aerosol formers include glycerin and propylene glycol. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (e.g., dimethyl dodecanedioate, dimethyl tetradecanedioate). The liquid aerosol-forming substrate may contain water, solvents, ethanol, plant extracts, and natural or artificial flavors. The liquid aerosol-forming substrate may contain nicotine and at least one aerosol former. The aerosol former may be glycerin or propylene glycol. The aerosol former may include both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of from about 0.5% to about 10%, for example about 2%.

[0074] According to a fourth embodiment of the present disclosure, there is provided a cartridge for an aerosol generation system. The cartridge may comprise an aerosol-forming substrate. The cartridge may comprise an aerosol-forming substrate as described in relation to the third embodiment. The aerosol-forming substrate may be in fluid communication with a wicking material.

[0075] The cartridge may include a heater assembly. The cartridge may include a heater assembly according to the first embodiment of the present disclosure. The cartridge may be configured to be coupled to an aerosol generating device. The heater assembly may be coupleable to and separable from the cartridge body. The heater assembly may include a heating element. The heater assembly may include a first electrical contact in electrical contact with a first end of the heating element. The heater assembly may include a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include multiple heating sections. The heating element may include at least one mounting section disposed between the heating sections along the continuous electrical path. The heater assembly may include a frame. The frame may include openings in the first plane. The heating element may be fixed to the frame. Each heating section may be within the opening. Each heating section may be above the opening. Each heating section may be separated from the frame by at least one mounting section. The heater assembly may further comprise a support structure. The frame may at least partially surround the support structure. The support structure may comprise a support structure opening. The support structure opening may be in a first plane. At least a portion of the heating element may be in the support structure opening. In particular, the plurality of heating portions may be in the support structure opening. At least a portion of the heating element may be above the support structure opening. In particular, the plurality of heating portions may be above the support structure opening. The support structure may comprise an upper support structure surface parallel to the first plane. Each mounting portion may comprise a first section and a second section. Each first section may be substantially parallel to the first plane. Each first section may be substantially coplanar with the upper support structure surface. Each second section may extend from the upper support structure surface toward a second plane. The second plane may be parallel to, but not coplanar with, the upper support structure surface. Advantageously, this arrangement provides a more robust structure for the heating element.

[0076] A cross-sectional area of each heating portion in a direction perpendicular to the direction of the continuous electrical path may be smaller than a cross-sectional area of each mounting portion in a direction perpendicular to the direction of the continuous electrical path. The heater assembly may form a portion of an outer surface of the cartridge. The wicking material may be in contact with the heating element.

[0077] The cartridge may further include a cartridge air flow path. The cartridge air flow path may be defined between the cartridge air inlet and the cartridge air outlet. The cartridge air flow path may be in fluid communication with the heating element. In particular, the cartridge air flow path may be in fluid communication with a first side of the heating element. The cartridge air flow path may pass through the heater assembly. The heater assembly may include a heater assembly air flow path between the heater assembly air inlet and the heater assembly air outlet. The cartridge air inlet may include a heater assembly air inlet.

[0078] The cartridge may be configured to be coupled to an aerosol generating device. The cartridge may be configured to be coupled to an aerosol generating device such that the cartridge air inlet is aligned with the device air outlet of the aerosol generating device.

[0079] The cartridge air outlet may comprise a mouthpiece.

[0080] The aerosol-forming substrate may be a liquid. In particular, the aerosol-forming substrate may be a liquid at standard temperature and pressure. Advantageously, this ensures that the liquid aerosol-forming substrate can be easily transferred from the reservoir to the wicking element and then to the heating element when the system is used at standard temperature and pressure.

[0081] 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 for at least a portion of the element to be heated to at least 50, 100, 150, 200, 250, or 300 degrees Celsius.

[0082] 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 device or the cartridge.

[0083] As used herein, the term "serpentine" is used to define a shape of a path that includes at least one curve or bend of approximately 180 degrees in the path, such that a first region of the shape lies along a second region of the shape when viewed perpendicular to the plane of the path. Thus, the shape may resemble a single Latin letter "S" or multiple Latin letter "S"s joined end-to-end.

[0084] As used herein, the terms "air inlet" and "air outlet" are used to describe one or more openings through which air may be drawn into and out of a heater assembly, aerosol generation system, cartridge or component or portion of a component of an aerosol generating device, respectively.

[0085] As used herein with respect to the present invention, the term "aerosol" is used to describe a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets in a gas. Aerosols can be visible or invisible. Aerosols may include vapors of substances that are normally liquids or solids at room temperature, as well as solid particulates, or liquid droplets, or a combination of solid particulates and liquid droplets.

[0086] As used herein, "aerosol-generating system" means a system that generates an aerosol from one or more aerosol-forming substrates.

[0087] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. [Example]

[0088] 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 one or more features of any of the other examples, embodiments, or aspects described herein.

[0089] Example 1 1. A heater assembly for an aerosol generating device, the heater assembly comprising: a heating element, the heating element comprising a plurality of heating portions and at least one mounting portion; a support structure having a support structure opening and an upper support structure surface parallel to the first plane; a frame, the frame at least partially surrounding the support structure; and a first electrical contact in electrical contact with the first end of the heating element; a second electrical contact in electrical contact with a second end of the heating element, the heating element forming a continuous electrical path between the first electrical contact and the second electrical contact; the heating element is secured to the frame, each heating section being within or over a support structure opening and separated from the frame by at least one mounting section; A heater assembly, wherein each mounting portion comprises a first section and a second section, each first section being substantially parallel to a first plane, and each second section extending from an upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface. Example 2. 10. The heater assembly of example 1, wherein each second section extends in a direction perpendicular to the surface of the upper support structure. Example 3. 3. The heater assembly of any one of claims 1 to 2, wherein at least a portion of the heating element is flush with the upper support structure surface. Example 4. 4. The heater assembly of example 3, wherein the plurality of heating sections are flush with the upper support structure surface. Example 5. 5. The heater assembly of any one of Examples 1-4, wherein each second section is secured between a frame and a support structure. Example 6 A heater assembly described in any one of Examples 1 to 5, wherein both the first and second electrical contacts comprise a first electrical contact section and a second electrical contact section, both first electrical contact sections being substantially parallel to the first plane, and both second electrical contact sections extending from the upper support structure surface toward the second plane. Example 7 7. The heater assembly of example 6, wherein both second electrical contact sections extend in a direction perpendicular to the upper support structure surface. Example 8 8. The heater assembly of example 6 or 7, wherein both second electrical contact sections are secured between the frame and the support structure. Example 9. 9. The heater assembly of any one of Examples 1-8, wherein the frame has an upper surface, the upper surface of the frame being coplanar with the upper support structure surface. Example 10. 10. The heater assembly of any one of Examples 1-9, wherein the frame has an upper surface, the upper surface of the frame being recessed from the surface of the upper support structure. Example 11 11. The heater assembly of any of Examples 1-10, wherein the frame has a lower surface, the support structure has a lower surface that is flush with the lower surface of the frame, both the first and second electrical contacts further comprise third electrical contact sections, and both third electrical contact sections are substantially flush with the lower surface of the frame. Example 12 12. The heater assembly of any one of Examples 1 to 11, wherein the electrical resistance of the plurality of heating portions is higher than the electrical resistance of at least one mounting portion. Example 13 13. The heater assembly of any one of Examples 1-12, wherein the cross-sectional area of each heating portion in a direction perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of each mounting portion in a direction perpendicular to the direction of the continuous electrical path. Example 14. A heater assembly described in any one of Examples 1 to 13, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating portions increases above the temperature of at least one mounting portion. Example 15. 15. The heater assembly of any one of Examples 1 to 14, wherein the plurality of heating portions and the at least one mounting portion are all integrally formed. Example 16. 16. The heater assembly of any one of Examples 1-15, wherein each attachment section directly connects to exactly two heating sections. Example 17. 17. The heater assembly of any one of Examples 1-16, wherein each heating section is directly connected to exactly two mounting sections, or exactly one mounting section and either the first electrical contact or the second electrical contact. Example 18. 18. A heater assembly according to any one of Examples 1 to 17, wherein each heating section has a first width in a first direction, and when a direction of a continuous electrical path is defined by each heating section, the first direction may be perpendicular to the direction of the continuous electrical path, and each mounting section has a second width in the first direction, the second width being greater than the first width. Example 19. 19. The heater assembly of Example 18, wherein a ratio of the first width to the second width is between 1 / 20 and 1 / 2. Example 20. 20. The heater assembly of example 19, wherein a ratio of the first width to the second width is between 1 / 10 and 1 / 4. Example 21. 21. The heater assembly of example 18, 19, or 20, wherein the first width is between 0.1 millimeters and 2 millimeters. Example 22. 22. The heater assembly of example embodiment 21, wherein the first width is between 0.2 millimeters and 1 millimeter. Example 23. 23. The heater assembly of example embodiment 22, wherein the first width is between 0.2 millimeters and 0.5 millimeters. Example 24. 24. The heater assembly of any one of Examples 18-23, wherein the heating element has a thickness in at least one direction perpendicular to the first direction. Example 25. 25. The heater assembly of example embodiment 24, wherein the thickness is between 0.02 millimeters and 0.5 millimeters. Example 26. 26. The heater assembly of example embodiment 25, wherein the thickness is between 0.05 millimeters and 0.3 millimeters. Example 27. A heater assembly described in any one of Examples 1 to 26, wherein the electrical resistance per unit length in the direction of the conductive path of multiple heating sections is greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting section. Example 28. The heater assembly of any one of Examples 1 to 27, wherein the heating element is serpentine shaped. Example 29. 29. The heater assembly of any one of Examples 1-28, wherein the heating element comprises stainless steel. Example 30. 30. The heater assembly of any one of Examples 1-29, wherein the heating element comprises a ferrimagnetic or ferromagnetic material. Example 31. 31. The heater assembly of any one of Examples 1-30, wherein the heating element is coated with a corrosion-resistant material. Example 32. 32. The heater assembly of any one of Examples 1-31, wherein the heating element is coated with a ceramic material. Example 33. 33. The heater assembly of any one of Examples 1-32, wherein the total resistance of the heating element is between 0.1 ohms and 5 ohms. Example 34. 34. The heater assembly of Example 33, wherein the total resistance of the heating element is between 0.2 ohms and 1.5 ohms. Example 35. The heater assembly of any one of Examples 1-34, wherein the heating element and the first and second electrical contacts are integrally formed. Example 36. The heater assembly of any one of Examples 1-35, wherein the heating element and the first and second electrical contacts are formed of the same material. Example 37. 37. The heater assembly of any one of Examples 1-36, wherein the support structure opening is approximately square or rectangular. Example 38. The heater assembly of any one of Examples 1-37, wherein the support structure opening is substantially circular. Example 39. The heater assembly of any one of Examples 1-38, wherein the frame is electrically insulating.

[0090] Example 40. 39. The heater assembly of claim 39, wherein the frame has a thermal conductivity of 1 W / mK or less. Example 41. 41. The heater assembly of example 39 or 40, wherein the frame comprises a heat resistant polymer. Example 42. 42. The heater assembly of any one of Examples 39-41, wherein the frame comprises polyetheretherketone (PEEK). Example 43. 43. The heater assembly of example 39 or 42, wherein the frame comprises ceramic. Example 44. 44. The heater assembly of example embodiment 43, wherein the frame comprises alumina. Example 45. 44. The heater assembly of example embodiment 43, wherein the frame comprises zirconia. Example 46. 46. The heater assembly of any one of Examples 1-45, wherein the support structure opening has a cross-sectional area in the first plane of between 1 square millimeter and 1000 square millimeters. Example 47. 47. The heater assembly of example embodiment 46, wherein the support structure opening has a cross-sectional area in the first plane of between 2 square millimeters and 200 square millimeters. Example 48. 48. The heater assembly of Example 47, wherein the support structure opening has a cross-sectional area in the first plane of between 4 square millimeters and 50 square millimeters. Example 49. 49. The heater assembly of any one of Examples 1-48, wherein each heating section has a radius of curvature perpendicular to the first plane. Example 50. 50. The heater assembly of any one of Examples 1-49, wherein the heating element comprises an elastic material. Example 51. 1. An aerosol generating device, comprising: a heater assembly; a heating element, the heating element comprising a plurality of heating portions and at least one mounting portion; a support structure having a support structure opening and an upper support structure surface parallel to the first plane; a frame, the frame at least partially surrounding the support structure; and a first electrical contact in electrical contact with the first end of the heating element; a second electrical contact in electrical contact with a second end of the heating element, the heating element forming a continuous electrical path between the first electrical contact and the second electrical contact; the heating element is secured to the frame, each heating section being within or over a support structure opening and separated from the frame by at least one mounting section; a heater assembly, wherein each mounting portion comprises a first section and a second section, each first section being substantially parallel to a first plane, and each second section extending from an upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface; an air flow path defined between the air inlet and the air outlet, the air flow path being in fluid communication with the heating element; a power supply in electrical contact with the first and second electrical contacts and configured to supply power to the heating element; An aerosol generating device comprising: a control circuit configured to control the supply of power from the power source to the heating element. Example 52. The aerosol generating device of Example 51, wherein the aerosol generating device is a portable aerosol generating device. Example 53. An aerosol generating device as described in Example 51 or 52, wherein the control circuit further comprises a suction detector in fluid communication with the air flow path, and the device is configured such that the heating element is suction-activated. Example 54. 54. An aerosol generating device according to any one of Examples 51 to 53, wherein the air inlet is defined in a side wall of the device. Example 55. 55. The aerosol generating device of Example 54, wherein the air outlet is defined in an end wall of the device. Example 56. 56. An aerosol generating device as described in Example 55, wherein the side wall of the device extends in a direction perpendicular to the end wall of the device. Example 57. An aerosol generating device according to any one of Examples 51 to 56, wherein each second section extends in a direction perpendicular to the upper support structure surface. Example 58. 58. The aerosol generating apparatus of any one of Examples 51 to 57, wherein at least a portion of the heating element is flush with the upper support structure surface. Example 59. An aerosol generating device as described in Example 58, wherein multiple heating sections are flush with the upper support structure surface. Example 60. 60. The aerosol generating device of Examples 51 to 59, wherein each second section is fixed between a frame and a support structure. Example 61. An aerosol generating device described in any one of Examples 51 to 60, wherein both the first and second electrical contacts have a first electrical contact section and a second electrical contact section, both first electrical contact sections are substantially parallel to the first plane, and both second electrical contact sections extend from the upper support structure surface toward the second plane. Example 62. An aerosol generating device as described in Example 61, wherein both second electrical contact sections extend in a direction perpendicular to the upper support structure surface. Example 63. An aerosol generating device as described in Example 61 or 62, wherein both second electrical contact sections are fixed between the frame and the support structure. Example 64. 64. The aerosol generating device of any one of Examples 51 to 63, wherein the frame has an upper surface, and the upper surface of the frame is flush with the upper support structure surface. Example 65. An aerosol generating device according to any one of Examples 51 to 64, wherein the frame has an upper surface, and the upper surface of the frame is recessed from the upper support structure surface. Example 66. An aerosol generating device described in any one of Examples 63 to 65, wherein the frame has a lower surface, the support structure has a lower surface that is flush with the lower surface of the frame, and both the first and second electrical contacts further have third electrical contact sections, and both third electrical contact sections are substantially flush with the lower surface of the frame. Example 67. 67. The aerosol generating device according to any one of Examples 51 to 66, wherein the electrical resistance of the plurality of heating parts is higher than the electrical resistance of at least one mounting part. Example 68. An aerosol generating device according to any one of Examples 51 to 67, wherein the cross-sectional area of each heating section in a direction perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of each mounting section in a direction perpendicular to the direction of the continuous electrical path. Example 69. An aerosol generating device described in any one of Examples 51 to 68, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating sections increases above the temperature of at least one mounting section. Example 70. 70. The aerosol generating device of any one of Examples 51 to 69, wherein the plurality of heating units and at least one mounting unit are all integrally formed. Example 71. An aerosol generating device according to any one of Examples 51 to 70, wherein each attachment part directly connects to exactly two heating parts. Example 72. An aerosol generating device described in any one of Examples 51 to 71, wherein each heating section is directly connected to exactly two mounting sections, or exactly one mounting section and either the first electrical contact or the second electrical contact. Example 73. An aerosol generating device described in any one of Examples 51 to 72, wherein each heating portion has a first width in a first direction, each mounting portion has a second width in the first direction, and the second width is larger than the first width. Example 74. 74. The aerosol generating device of Example 73, wherein the ratio of the first width to the second width is 1 / 20 to 1 / 2. Example 75. 75. The aerosol generating device of Example 74, wherein the ratio of the first width to the second width is 1 / 10 to 1 / 4. Example 76. 76. An aerosol generating device according to any one of Examples 73, 74, or 75, wherein the first width is between 0.1 millimeters and 2 millimeters. Example 77. 77. The aerosol generating device of Example 76, wherein the first width is 0.2 millimeters to 1 millimeter. Example 78. 78. The aerosol generating device of Example 77, wherein the first width is 0.2 millimeters to 0.5 millimeters. Example 79. 79. The aerosol generating device of any one of Examples 76 to 78, wherein the heating element has a thickness in at least one direction perpendicular to the first direction.

[0091] Example 80. The aerosol generating device of Example 79, having a thickness of 0.02 millimeters to 0.5 millimeters. Example 81. The aerosol generating device described in Example 80, having a thickness of 0.05 millimeters to 0.3 millimeters. Example 82. An aerosol generating device described in any one of Examples 51 to 81, wherein the electrical resistance per unit length in the direction of the conductive path of multiple heating parts is greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting part. Example 83. 83. The aerosol generating apparatus according to any one of Examples 51 to 82, wherein the heating element has a serpentine shape. Example 84. 84. The aerosol generating device of any one of Examples 51 to 83, wherein the heating element comprises stainless steel. Example 85. 85. The aerosol generating apparatus of any one of Examples 51 to 84, wherein the heating element comprises a ferrimagnetic or ferromagnetic material. Example 86. 86. The aerosol generating apparatus of any one of Examples 51 to 85, wherein the heating element is coated with a corrosion-resistant material. Example 87. 87. The aerosol generating device of any one of Examples 51 to 86, wherein the heating element is coated with a ceramic material. Example 88. 88. The aerosol generating apparatus according to any one of Examples 51 to 87, wherein the total resistance of the heating element is 0.1 ohms to 5 ohms. Example 89. The aerosol generating device described in Example 88, wherein the total resistance of the heating element is 0.2 ohms to 1.5 ohms. Example 90. 89. The aerosol generating device of any one of Examples 51 to 89, wherein the heating element and the first and second electrical contacts are integrally formed. Example 91. An aerosol generating device according to any one of Examples 51 to 90, wherein the heating element and the first and second electrical contacts are formed from the same material. Example 92. An aerosol generating device according to any one of Examples 51 to 91, wherein the support structure opening is approximately square or rectangular. Example 93. An aerosol generating device according to any one of Examples 51 to 91, wherein the support structure opening is substantially circular. Example 94. 94. The aerosol generating apparatus according to any one of Examples 51 to 93, wherein the frame is electrically insulating. Example 95. An aerosol generating device as described in Example 94, wherein the frame has a thermal conductivity of 1 W / mK or less. Example 96. An aerosol generating device as described in Example 94 or 95, wherein the frame comprises a heat-resistant polymer. Example 97. 97. The aerosol generating device of any one of Examples 94 to 96, wherein the frame comprises polyetheretherketone (PEEK). Example 98. 96. An aerosol generating device as described in Example 94 or 95, wherein the frame comprises ceramic. Example 99. 99. The aerosol generating device of example 98, wherein the frame comprises alumina. Example 100. 99. The aerosol generating device of example 98, wherein the frame comprises zirconia. Example 101. 101. An aerosol generating device according to any one of Examples 51 to 100, wherein the support structure opening has a cross-sectional area in the first plane of between 1 square millimeter and 1000 square millimeters. Example 102. 102. An aerosol generating device as described in Example 101, wherein the support structure opening has a cross-sectional area in the first plane of 2 square millimeters to 200 square millimeters. Example 103. 103. An aerosol generating device as described in Example 102, wherein the support structure opening has a cross-sectional area in the first plane of 4 square millimeters to 50 square millimeters. Example 104. 104. The aerosol generating apparatus according to any one of Examples 51 to 103, wherein each heating element has a radius of curvature perpendicular to the first plane. Example 105. The aerosol generating device of any one of Examples 51 to 104, wherein the heating element comprises an elastic material. Example 106. 1. An aerosol generating system comprising: A cartridge, comprising: an aerosol-forming substrate in fluid communication with the wicking material, a cartridge comprising an aerosol-forming substrate, the wicking material forming part of the outer surface of the cartridge; An aerosol generating device, comprising: A heater assembly, comprising: a heating element, the heating element comprising a plurality of heating portions and at least one mounting portion; a support structure having a support structure opening and an upper support structure surface parallel to the first plane; a frame, the frame at least partially surrounding the support structure; and a first electrical contact in electrical contact with the first end of the heating element; a second electrical contact in electrical contact with a second end of the heating element, the heating element forming a continuous electrical path between the first electrical contact and the second electrical contact; the heating element is secured to the frame, each heating section being within or over a support structure opening and separated from the frame by at least one mounting section; a heater assembly, wherein each mounting portion comprises a first section and a second section, each first section being substantially parallel to a first plane, and each second section extending from an upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface; an air flow path defined between the air inlet and the air outlet, the air flow path being in fluid communication with the heating element; a power supply in electrical contact with the first and second electrical contacts and configured to supply power to the heating element; a control circuit configured to control the supply of power from the power source to the heating element; and An aerosol generating system, wherein the cartridge is reversibly coupleable to an aerosol generating device such that the wicking material is in direct contact with the heating element when the cartridge is coupled to the device. Example 107. An aerosol generation system as described in Example 106, wherein the air flow path is in fluid communication with a first side of the heating element and the wicking material is in direct contact with a second side of the heating element when the cartridge is connected to the device. Example 108. An aerosol generation system as described in Example 106 or 107, wherein the cartridge further comprises an air flow path of the cartridge defined between the air inlet of the cartridge and the air outlet of the cartridge. Example 109. An aerosol generation system as described in Example 108, wherein when the cartridge is connected to the device, the air intake of the cartridge is in fluid communication with the air outlet of the device. Example 110. An aerosol generation system as described in Example 108 or 109, wherein the air outlet of the cartridge is equipped with a mouthpiece. Example 111. 111. The aerosol-generating system of any one of Examples 106 to 110, wherein the aerosol-forming substrate is liquid at standard temperature and pressure. Example 112. An aerosol generation system described in any one of Examples 106 to 111, wherein each second section extends in a direction perpendicular to the upper support structure surface. Example 113. 113. The aerosol generating system of any one of Examples 106-112, wherein at least a portion of the heating element is flush with the upper support structure surface. Example 114. An aerosol generating system as described in Example 113, wherein multiple heating sections are flush with the upper support structure surface. Example 115. An aerosol generation system described in any one of Examples 106 to 114, wherein each second section is fixed between a frame and a support structure. Example 116. An aerosol generation system described in any one of Examples 106 to 115, wherein both the first and second electrical contacts have a first electrical contact section and a second electrical contact section, both first electrical contact sections are substantially parallel to the first plane, and both second electrical contact sections extend from the upper support structure surface toward the second plane. Example 117. An aerosol generation system as described in Example 116, wherein both second electrical contact sections extend in a direction perpendicular to the upper support structure surface. Example 118. An aerosol generation system as described in Example 116 or 117, wherein both second electrical contact sections are fixed between the frame and the support structure. Example 119. 119. The aerosol generating system of any one of Examples 106-118, wherein the frame has an upper surface, and the upper surface of the frame is flush with the upper support structure surface. Example 120. An aerosol generating system as described in Examples 106-119, wherein the frame has an upper surface, and the upper surface of the frame is recessed from the upper support structure surface.

[0092] Example 121. An aerosol generation system described in any one of Examples 118 to 120, wherein the frame has a lower surface, the support structure has a lower surface that is flush with the lower surface of the frame, and both the first and second electrical contacts further have third electrical contact sections, and both third electrical contact sections are substantially flush with the lower surface of the frame. Example 122. 122. The aerosol generating system of any one of Examples 106 to 121, wherein the electrical resistance of the plurality of heating portions is higher than the electrical resistance of at least one mounting portion. Example 123. An aerosol generating system as described in Examples 106 to 122, wherein the cross-sectional area of each heating section in a direction perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of each mounting section in a direction perpendicular to the direction of the continuous electrical path. Example 124. An aerosol generation system described in any one of Examples 106 to 123, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating sections increases above the temperature of at least one mounting section. Example 125. An aerosol generating system described in any one of Examples 106 to 124, wherein the plurality of heating sections and at least one mounting section are all integrally formed. Example 126. An aerosol generation system described in any one of Examples 106 to 125, wherein each attachment section directly connects to exactly two heating sections. Example 127. An aerosol generation system described in any one of Examples 106 to 126, wherein each heating section is directly connected to exactly two attachment sections, or exactly one attachment section and either the first electrical contact or the second electrical contact. Example 128. An aerosol generating system described in any one of Examples 106 to 127, wherein each heating portion has a first width in a first direction, each mounting portion has a second width in the first direction, and the second width is greater than the first width. Example 129. An aerosol generation system as described in Example 128, wherein the ratio of the first width to the second width is 1 / 20 to 1 / 2. Example 130. 129. The aerosol generation system of Example 129, wherein the ratio of the first width to the second width is 1 / 10 to 1 / 4. Example 131. 131. The aerosol generation system of Example 128, 129, or 130, wherein the first width is between 0.1 millimeters and 2 millimeters. Example 132. 132. The aerosol generation system of Example 131, wherein the first width is between 0.2 millimeters and 1 millimeter. Example 133. An aerosol generation system as described in Example 132, wherein the first width is 0.2 millimeters to 0.5 millimeters. Example 134. An aerosol generating system according to any one of Examples 128 to 133, wherein the heating element has a thickness in at least one direction perpendicular to the first direction. Example 135. The aerosol generating system of Example 134, having a thickness of 0.02 millimeters to 0.5 millimeters. Example 136. The aerosol generating system of Example 135, having a thickness of 0.05 millimeters to 0.3 millimeters. Example 137. An aerosol generating system described in any one of Examples 106 to 136, wherein the electrical resistance per unit length in the direction of the conductive path of multiple heating sections is greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting section. Example 138. 138. The aerosol generating system of any one of Examples 106 to 137, wherein the heating element has a serpentine shape. Example 139. The aerosol generating system of any one of Examples 106-138, wherein the heating element comprises stainless steel. Example 140. 139. The aerosol generating system of any one of Examples 106-139, wherein the heating element comprises a ferrimagnetic or ferromagnetic material. Example 141. 141. The aerosol generating system of any one of Examples 106-140, wherein the heating element is coated with a corrosion-resistant material. Example 142. 142. The aerosol generating system of any one of Examples 106-141, wherein the heating element is coated with a ceramic material. Example 143. An aerosol generating system described in any one of Examples 106 to 142, wherein the total resistance of the heating element is between 0.1 ohms and 5 ohms. Example 144. An aerosol generation system as described in Example 143, wherein the total resistance of the heating element is 0.2 ohms to 1.5 ohms. Example 145. An aerosol generating system described in any one of Examples 106 to 144, wherein the heating element and the first and second electrical contacts are integrally formed. Example 146. An aerosol generation system described in any one of Examples 106 to 145, wherein the heating element and the first and second electrical contacts are formed from the same material. Example 147. An aerosol generation system described in any one of Examples 106 to 146, wherein the support structure opening is approximately square or rectangular. Example 148. An aerosol generation system described in any one of Examples 106 to 146, wherein the support structure opening is approximately circular. Example 149. The aerosol generating system according to any one of Examples 106 to 148, wherein the frame is electrically insulating. Example 150. An aerosol generation system as described in Example 149, wherein the frame has a thermal conductivity of 1 W / mK or less. Example 151. An aerosol generating system as described in Example 149 or 150, wherein the frame comprises a heat-resistant polymer. Example 152. 152. The aerosol generating system of any one of Examples 149 to 151, wherein the frame comprises polyetheretherketone (PEEK). Example 153. An aerosol generation system as described in Example 149 or 150, wherein the frame comprises ceramic. Example 154. The aerosol generating system of Example 153, wherein the frame comprises alumina. Example 155. The aerosol generating system of example 153, wherein the frame comprises zirconia. Example 156. An aerosol generation system described in any one of Examples 106 to 155, wherein the support structure opening has a cross-sectional area in the first plane of between 1 square millimeter and 1000 square millimeters. Example 157. An aerosol generation system as described in Example 156, wherein the support structure opening has a cross-sectional area in the first plane of 2 square millimeters to 200 square millimeters. Example 158. An aerosol generation system as described in Example 157, wherein the support structure opening has a cross-sectional area in the first plane of 4 square millimeters to 50 square millimeters. Example 159. An aerosol generation system described in any one of Examples 106 to 158, wherein each heating section has a radius of curvature perpendicular to the first plane. Example 160. The aerosol generating system of any one of Examples 106 to 159, wherein the heating element comprises an elastic material. Example 161. 1. A cartridge for an aerosol generation system, the cartridge comprising: an aerosol-forming substrate in fluid communication with the wicking material; 1. A heater assembly, comprising: a heating element, the wicking material being in contact with the heating element, the heating element comprising a plurality of heating portions and at least one attachment portion; a support structure having a support structure opening and an upper support structure surface parallel to the first plane; a frame, the frame at least partially surrounding the support structure; and a first electrical contact in electrical contact with the first end of the heating element; a second electrical contact in electrical contact with a second end of the heating element, the heating element forming a continuous electrical path between the first electrical contact and the second electrical contact; the heating element is secured to the frame, each heating section being within or over a support structure opening and separated from the frame by at least one mounting section; a heater assembly, wherein each mounting portion comprises a first section and a second section, each first section being substantially parallel to a first plane, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface. Example 162. The cartridge described in Example 161, wherein the cartridge is configured to be reversibly connectable to and detachable from the aerosol generating device. Example 163. 163. The cartridge of example 161 or 162, further comprising an air flow path of the cartridge defined between the air inlet of the cartridge and the air outlet of the cartridge. Example 164. The cartridge of Example 163, wherein the air outlet of the cartridge is provided with a mouthpiece. Example 165. 165. A cartridge according to any of Examples 161 to 164, wherein the aerosol-forming substrate is liquid at standard temperature and pressure. Example 166. The cartridge of any one of Examples 161 to 165, wherein each second section extends in a direction perpendicular to the upper support structure surface. Example 167. The cartridge of any one of Examples 161 to 166, wherein at least a portion of the heating element is flush with the upper support structure surface. Example 168. A cartridge as described in Example 167, wherein the multiple heating sections are flush with the upper support structure surface. Example 169. The cartridge of any one of Examples 161 to 168, wherein each second section is secured between a frame and a support structure.

[0093] Example 170. A cartridge described in any one of Examples 161 to 169, wherein both the first and second electrical contacts comprise a first electrical contact section and a second electrical contact section, both first electrical contact sections being substantially parallel to the first plane, and both second electrical contact sections extending from the upper support structure surface toward the second plane. Example 171. A cartridge as described in Example 170, wherein both second electrical contact sections extend in a direction perpendicular to the upper support structure surface. Example 172. 172. The cartridge of example 170 or 171, wherein both second electrical contact sections are fixed between the frame and the support structure. Example 173. 173. The cartridge of any one of Examples 161 to 172, wherein the frame has an upper surface, the upper surface of the frame being flush with the upper support structure surface. Example 174. The cartridge of any one of Examples 161 to 173, wherein the frame has an upper surface, the upper surface of the frame being recessed from the surface of the upper support structure. Example 175. A cartridge described in any one of Examples 172 to 174, wherein the frame has a lower surface, the support structure has a lower surface that is flush with the lower surface of the frame, and both the first and second electrical contacts further have third electrical contact sections, and both third electrical contact sections are substantially flush with the lower surface of the frame. Example 176. The cartridge of any one of Examples 161 to 175, wherein the electrical resistance of the plurality of heating portions is higher than the electrical resistance of at least one mounting portion. Example 177. A cartridge described in any one of Examples 161 to 176, wherein the cross-sectional area of each heating section in a direction perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of each mounting section in a direction perpendicular to the direction of the continuous electrical path. Example 178. A cartridge described in any one of Examples 161 to 177, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating portions increases above the temperature of at least one mounting portion. Example 179. The cartridge of any one of Examples 161 to 178, wherein the plurality of heating portions and the at least one mounting portion are all integrally formed. Example 180. The cartridge of any one of Examples 161 to 179, wherein each mounting portion directly connects to exactly two heating portions. Example 181. A cartridge described in any one of Examples 161 to 180, wherein each heating portion is directly connected to exactly two mounting portions, or exactly one mounting portion and either the first electrical contact or the second electrical contact. Example 182. A cartridge described in any one of Examples 161 to 181, wherein each heating portion has a first width in a first direction, each mounting portion has a second width in the first direction, and the second width is larger than the first width. Example 183. The cartridge of Example 182, wherein the ratio of the first width to the second width is 1 / 20 to 1 / 2. Example 184. The cartridge of Example 183, wherein the ratio of the first width to the second width is 1 / 10 to 1 / 4. Example 185. 185. The cartridge of example 182, 183, or 184, wherein the first width is between 0.1 millimeters and 2 millimeters. Example 186. The cartridge of Example 185, wherein the first width is between 0.2 millimeters and 1 millimeter. Example 187. The cartridge of Example 186, wherein the first width is between 0.2 millimeters and 0.5 millimeters. Example 188. The cartridge of any one of Examples 161 to 187, wherein the heating element has a thickness in at least one direction perpendicular to the first direction. Example 189. The cartridge of Example 188, having a thickness of 0.02 millimeters to 0.5 millimeters. Example 190. The cartridge of Example 189, having a thickness of 0.05 millimeters to 0.3 millimeters. Example 191. A cartridge described in any one of Examples 161 to 190, wherein the electrical resistance per unit length in the direction of the conductive path of multiple heating sections is greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting section. Example 192. The cartridge of any one of Examples 161 to 191, wherein the heating element has a serpentine shape. Example 193. The cartridge of any one of Examples 161-192, wherein the heating element comprises stainless steel. Example 194. The cartridge of any one of Examples 161 to 193, wherein the heating element comprises a ferrimagnetic or ferromagnetic material. Example 195. The cartridge of any one of Examples 161 to 194, wherein the heating element is coated with a corrosion-resistant material. Example 196. The cartridge of any one of Examples 161 to 195, wherein the heating element is coated with a ceramic material. Example 197. The cartridge of any one of Examples 161 to 196, wherein the total resistance of the heating element is 0.1 ohms to 5 ohms. Example 198. The cartridge of Example 197, wherein the total resistance of the heating element is between 0.2 ohms and 1.5 ohms. Example 199. The cartridge of any one of Examples 161 to 198, wherein the heating element and the first and second electrical contacts are integrally formed. Example 200. The cartridge of any one of Examples 161-199, wherein the heating element and the first and second electrical contacts are formed of the same material. Example 201. A cartridge described in any one of Examples 161 to 200, wherein the support structure opening is approximately square or rectangular. Example 202. The cartridge of any one of Examples 161 to 201, wherein the support structure opening is substantially circular. Example 203. The cartridge of any one of Examples 161 to 202, wherein the frame is electrically insulating. Example 204. The cartridge of Example 203, wherein the frame has a thermal conductivity of 1 W / mK or less. Example 205. The cartridge of example 203 or 204, wherein the frame comprises a heat-resistant polymer. Example 206. The cartridge of any one of Examples 203 to 205, wherein the frame comprises polyetheretherketone (PEEK). Example 207. 205. The cartridge of example 203 or 204, wherein the frame comprises ceramic. Example 208. The cartridge of example 207, wherein the frame comprises alumina. Example 209. 208. The cartridge of example 207, wherein the frame comprises zirconia. Example 210. The cartridge of any one of Examples 161 to 209, wherein the support structure opening has a cross-sectional area in the first plane of 1 square millimeter to 1000 square millimeters. Example 211. 211. The cartridge of example 210, wherein the support structure opening has a cross-sectional area in the first plane of between 2 square millimeters and 200 square millimeters. Example 212. The cartridge of example 211, wherein the support structure opening has a cross-sectional area in the first plane of between 4 square millimeters and 50 square millimeters.

[0094] Features of one aspect or embodiment of the invention may be applied to other aspects or embodiments of the invention.

[0095] The embodiments will now be further described with reference to the figures. [Brief explanation of the drawings]

[0096] [Figure 1A] FIG. 1A shows a perspective view of the heater assembly. [Figure 1B] FIG. 1B shows a top view of the heater assembly of FIG. 1A. [Figure 1C] FIG. 1C shows a side view of the heater assembly of FIG. 1A. [Figure 2A] FIG. 2A shows a perspective view of another heater assembly. [Figure 2B] FIG. 2B shows a top view of the heater assembly of FIG. 2A. [Figure 3A] FIG. 3A shows a perspective view of another heater assembly. [Figure 3B]FIG. 3B shows a side view of the heater assembly of FIG. 3A. [Figure 4A] FIG. 4A shows a perspective view of yet another heater assembly. [Figure 4B] FIG. 4B shows a perspective view of the heater assembly of FIG. 4A, with selected components of the heater assembly shown in transparency. [Figure 5] FIG. 5 shows a schematic cross-sectional view of an aerosol generating device comprising a heater assembly as shown in any of FIGS. 1A-4B. [Figure 6] FIG. 6 shows a schematic cross-sectional view of an aerosol generation system, which comprises the aerosol generation device shown in FIG. 5 and a cartridge connected to the aerosol generation device. [Figure 7] FIG. 7 shows a schematic cross-sectional view of a cartridge according to yet another embodiment, the cartridge including the heater assembly shown in any of FIGS. 1A-4B. DETAILED DESCRIPTION OF THE INVENTION

[0097] 1A shows a perspective view of a heater assembly 100. The heater assembly 100 is for use in an aerosol generating system, such as an electrically operated smoking system, often referred to as an e-cigarette system. The aerosol generating system is a handheld portable system, similar in size to a traditional cigar or cigarette.

[0098] The heater assembly 100 includes a frame 120. The frame 120 has a length and a width in a first plane and a height perpendicular to the first plane, the length and width being greater than the height. Thus, the frame 120 has an upper surface extending in the first plane. The frame 120 is generally square in shape in the first plane. The corners of the frame 120 in the first plane are rounded. The frame 120 includes an opening 121, which is disposed in the center of the frame 120. The opening 121 penetrates the frame in a direction perpendicular to the first plane. The opening 121 is generally square in shape parallel to the first plane. In this embodiment, the opening 121 has the same shape as the frame 120, but this is not necessarily the case. The area of the opening is 100 mm. 2 For example, a generally square shaped frame may include a generally circular opening. In the embodiment shown in Figure 1A, the frame is formed from a heat resistant polymer, such as PEEK, although other suitable materials may be used instead.

[0099] The heater assembly 100 further includes a heating element 130. In the embodiment shown in FIG. 1A, the heating element 130 is parallel to the first plane. The heating element 130 includes a plurality of heating portions 131 and at least one mounting portion 132. In the embodiment shown in FIG. 1A, the heating element 130 includes seven heating portions 131 and six mounting portions 132. In the embodiment shown in FIG. 1A, the plurality of heating portions 131 and the at least one mounting portion 132 are integrally formed and comprise stainless steel.

[0100] The heater assembly 100 further includes a first electrical contact 191 and a second electrical contact 192. The first electrical contact 191 is attached to a first end of the heating element 130. The second electrical contact 192 is attached to a second end of the heating element 130. The heating element 130 forms a continuous, serpentine electrical path between the first electrical contact 191 and the second electrical contact 192. This continuous electrical path has a total electrical resistance of approximately 1 ohm. A portion of the heating element 130 overlies the opening 121. Specifically, a section of each heating portion 131 and mounting portion 132 overlies the opening 121. Portions of the first electrical contact 191 and the second electrical contact 192 protrude from opposite sides of the frame 120 to allow electrical connection to external electronics.

[0101] The mounting portions 132 are each attached to the frame 120. In this particular embodiment, the frame 120 is overmolded onto the mounting sections of the mounting portions 132. The first electrical contact 191 and the second electrical contact 192 are also attached to the frame 120. Specifically, in this embodiment, the frame 120 is overmolded onto the mounting sections of the first electrical contact 191 and the second electrical contact 192. However, in other embodiments, instead of overmolding the frame onto the mounting sections, the two frame elements could either be snap-fit, press-fit, or fastened together.

[0102] The heating element 130 and the first and second electrical contacts 191, 192 are integrally formed and cut from a flat metal sheet, for example by laser cutting, water jet cutting, or chemical etching.

[0103] In this first embodiment, the heating element 130 is uncoated, however, the heating element 130 may be coated with a thin layer of a corrosion-resistant material to extend the life of the heating element 130. An example of such a material is a ceramic material.

[0104] FIG. 1B shows a plan view of the heater assembly 100 according to the embodiment of FIG. 1A. The heating portion 131 is shown having a first width 141 in a first direction, and the mounting portion is also shown having a second width 142 in the first direction. The second width is wider than the first width. The first width is approximately 0.5 millimeters. The second width is approximately 1.5 millimeters. Thus, the ratio of the first width to the second width is approximately 1 / 3. The serpentine shape of the heating element 130 is more clearly seen in this plan view. The heating portion 131 is shown to have a constant width along its entire length equal to the first width in the first direction. The mounting portion 131 is also shown to have a constant width along its entire length equal to the second width in the first direction.

[0105] FIG. 1C shows a side view of the heater assembly 100 according to the embodiment of FIGS. 1A and 1B. The side view is in a first plane. The heating element 130 is seen to be substantially planar in the first plane, as it extends much further in the first plane than in a direction perpendicular to the first plane. The heating element 130 is shown to have a uniform thickness in a direction perpendicular to the first plane. The thickness of the heating element is approximately 0.1 millimeters. Thus, the heating portion 131 and the mounting portion 132 have approximately equal thicknesses in a direction perpendicular to the first plane. The heating element 130 is recessed from the top surface 122 of the frame 120 by approximately 2 millimeters. Similarly, the first and second electrical contacts 191, 192 are recessed from the top surface 122 of the frame 120 by approximately 2 millimeters. Similarly, the heating element 130 and the first and second electrical contacts are recessed from the underside of the frame 120 .

[0106] The heater assembly 100 is configured to couple to a wicking element, where the wicking element is in direct contact with one side of the heating element 130, and the other side of the heating element 130 may be exposed to air.

[0107] When a current flows through the heating element 130 or when a non-zero voltage is applied between the first electrical contact 191 and the second electrical contact 192, the heating element 130 heats up as a result of resistive heating. The current passes through the continuous electrical path formed by the heating element 130 in a serpentine direction defined by the shape of the heating element 130. Because the first width is greater than the second width and the heating portions 131 and the mounting portions 132 have approximately equal thicknesses perpendicular to the first plane, the cross-sectional area of each heating portion 131 perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of each mounting portion 132 perpendicular to the direction of the continuous electrical path. Therefore, when a current flows through the heating element 130 or when a non-zero voltage is applied between the first electrical contact 191 and the second electrical contact 192, the temperature of the heating portion 131 increases more than the temperature of the mounting portions 132.

[0108] The effect of increasing the temperature of the heating portion 131 above that of the attachment portion 132 can be achieved in other ways. For example, the thicknesses of the heating portion and the attachment portion may be different.

[0109] FIG. 2A shows a perspective view of a heater assembly 200 according to another embodiment. The frame 220 and the opening 221 are the same as those shown in FIGS. 1A-1C. The heater assembly 200 includes a heating element 230, which, like the first embodiment, includes multiple heating sections 231 and at least one mounting section 232. The heater assembly 200 also includes a first electrical contact 291 and a second electrical contact 292, like the first embodiment. This embodiment differs from the embodiment of FIG. 1A in that the heating element 230 further includes at least one insulating section 235. In the embodiment shown in FIG. 2A, the heating element 230 includes six insulating sections 235. The number of insulating sections 235 is equal to the number of mounting sections 232. Each insulating section 235 is connected between the frame 220 and one of the mounting sections 232. Specifically, in the second embodiment, the frame 120 is overmolded onto each section of the insulating section 235. 2A, the plurality of heating sections 231, the at least one mounting section 232, and the at least one insulating section 235 are integrally formed and comprise stainless steel. The plurality of heating sections 231, the at least one mounting section 232, and the at least one insulating section 235 have approximately equal thicknesses in a direction perpendicular to the first plane.

[0110] FIG. 2B shows a plan view of the heater assembly of FIG. 2A. Similar to the embodiment of FIG. 1A, the heating portion 231 is shown having a first width 241 in a first direction, and the mounting portion is also shown having a second width 242 in the first direction. The second width is wider than the first width. In this second embodiment, the insulating portion 235 has a third width in the first direction. The second width is wider than the third width. The third width is approximately 0.75 millimeters. Thus, the ratio of the third width to the second width is approximately 1 / 2. In the embodiment shown, the third width is wider than the first width, but this may not necessarily be the case. For example, the third width may be approximately equal to the first width or narrower than the first width. The thicknesses of the plurality of heating portions 231, at least one mounting portion 232, and at least one insulating portion 235.

[0111] When a current flows through the heating element 230, or when a non-zero voltage is applied between the first electrical contact 291 and the second electrical contact 292, the heating portion 231 and the mounting portion 232 heat up as a result of resistive heating. As described with respect to FIGS. 1A-1C, the temperature of the mounting portion 232 increases less than the temperature of the heating portion 231, but the mounting portion 232 may reach a temperature where direct contact between the mounting portion 232 and the frame 220 is undesirable. Because the third width of the insulating portion 235 is narrower than the second width of the mounting portion 232, when a current flows through the heating element 230, the amount of energy transferred from the mounting portion to the frame 220 is less than if the mounting portion 232 were instead attached to the frame 220, such as in the first embodiment.

[0112] FIG. 3A shows a perspective view of a heater assembly according to another embodiment. The frame 320 and opening 321 are the same as those shown in FIGS. 1A-1C and 2A-2B. The heater assembly 300 includes a heating element 330, which, like the first and second embodiments, includes a plurality of heating sections 331 and at least one mounting section 332. The heater assembly 300 also includes a first electrical contact 391 and a second electrical contact 392, like the embodiments of FIGS. 1A-C and 2A-2B. This alternative embodiment differs from the embodiment of FIG. 1A in the shape of the heating element 330, which can also be seen in FIG. 3B.

[0113] 3B shows a side view of a heater assembly according to another embodiment. Each of the plurality of heating sections 331 has a radius of curvature perpendicular to the first plane. The outer surface of the curved heating section 331 is configured to be coupled to a wicking element.

[0114] The mounting section of the mounting portion 332 and the sections of the first and second electrical contacts 391, 392 are recessed approximately 2 millimeters from the top surface 322 of the frame 320. Similarly, the mounting section of the mounting portion 332 and the sections of the first and second electrical contacts 391, 392 are recessed from the bottom surface of the frame 320. The mounting portion 332 and the first and second electrical contacts 391, 392 include two sets of approximately 90-degree bends. A first set of approximately 90-degree bends 336 orient the mounting portion 332 and the first and second electrical contacts 391, 392 so that they extend in a direction perpendicular to the first plane. A second set of approximately 90-degree bends 337 orient the mounting portion 332 and the first and second electrical contacts 391, 392 away from a direction perpendicular to the first plane. Thus, two sets of approximately 90 degree bends are positioned such that a plurality of heating sections 331 intersect the top surface 322 of the frame 320, with at least a portion of each heating section 331 extending beyond the plane formed by the top surface 322 of the frame 320. In this alternative embodiment, the heating element is bent by cold stamping or microbending.

[0115] FIG. 4A shows a perspective view of a heater assembly according to yet another embodiment. The heater assembly 400 includes a heating element 430, which includes a plurality of heating sections 431 and at least one mounting section 432, similar to the previous embodiment. The heater assembly 400 also includes a first electrical contact 491 and a second electrical contact 492, similar to the previous embodiment. In contrast to the first embodiment, in this yet another embodiment, the heater assembly 400 further includes a support structure 460. The frame 420 surrounds the support structure 460 in a first plane. The support structure 460 can be considered to be disposed within an opening in the frame 420. The frame 420 includes a circular periphery and a generally oval-shaped opening. The support structure 460 includes a generally oval-shaped periphery that is the same size and shape as the generally oval-shaped opening in the frame to minimize a gap between the frame 420 and the support structure 460. The support structure 460 includes a generally oval-shaped support structure opening 461 in a first plane. The support structure 460 includes an upper support structure surface 462 that is parallel to the first plane and coplanar with the top surface 422 of the frame 420. The plurality of heating elements 431 are coplanar with the upper support structure surface 462 and above the support structure opening 461.

[0116] FIG. 4B shows a perspective view of the heater assembly of FIG. 4A, with selected components of the heater assembly shown as transparent. Specifically, the frame 420 and the support structure 460 are shown as transparent. Each mounting portion 432 includes a first section 433 and a second section 434. Each first section 433 rests on the upper support structure surface 462 and can therefore be considered to be coplanar with the upper support structure surface 462. Each mounting portion 432 further includes a first set of approximately 90-degree bends 437. The first set of 90-degree bends orient each second section 434 so that the second section 434 extends from the upper support structure surface 462 in a direction perpendicular to the upper support structure surface 462. Thus, each second section 434 is disposed between the frame 420 and the support structure 460.

[0117] Additionally, both the first and second electrical contacts 491, 492 include a first electrical contact section 493, a second electrical contact section 494, and a third electrical contact section 495. Similar to the mounting portion 432, both the first electrical contact sections 493 are substantially flush with the upper support structure surface 462. Both the first and second electrical contacts 491, 492 further include two approximately 90-degree bends 497, 496. The first pair of 90-degree bends 497 orient both second electrical contact sections 494 such that they extend from the upper support structure surface 462 in a direction perpendicular to the upper support structure surface 462. Thus, both second electrical contact sections 494 are disposed between the frame 420 and the support structure 460. A second pair of 90 degree bends 498 orients the third electrical contact section 495 so that it is flush with the underside of the frame and parallel to the first plane. In this embodiment, the heating element is bent by cold stamping or microbending.

[0118] FIG. 5 shows a cross-sectional schematic view of an aerosol generating device 510, comprising a heater assembly 500 according to any of the previously described embodiments.

[0119] The aerosol generating device 510 is an electrically operated smoking device, often referred to as an e-cigarette system. The aerosol generating device 510 is a handheld portable device, and is similar in size to a traditional cigar or cigarette.

[0120] The device 510 includes a battery 511 , for example a lithium iron phosphate battery, and a controller 512 in electrical communication with the battery 511 .

[0121] Device 510 comprises an outer casing 517. The outer casing houses a battery 511 and a controller 512. Device 510 is configured to couple to a cartridge comprising a wicking element and an aerosol-forming substrate. Device 510 comprises a cartridge connector 518 extending from the proximal end of device 510. Cartridge connector 518 extends annularly from outer casing 517 and defines a space capable of receiving a cartridge therein.

[0122] Heater assembly 500 includes a fluid-permeable heating element 530 and a frame 520, both of which are described in previous embodiments. First and second electrical contacts (not shown) electrically connect heating element 530, battery 511, and controller 512.

[0123] The device 510 comprises a device air inlet 513 and a device air outlet 514. The device air inlet 513 is defined in a sidewall of the device 610. The device air outlet is defined at the proximal end of the device. The device 510 comprises a device air flow path 519. The device air flow path 519 is defined between the device air inlet 513 and the device air outlet 514. The heating element 530 is disposed downstream of the device air inlet 513 and upstream of the device air outlet 514 and is in fluid communication with the device air flow path 519. Specifically, a lower portion of the heating element 530 is in fluid communication with the device air flow path 519. It can be seen that the device air flow path 519 comprises a heater assembly air flow path. The heater assembly air flow path is defined between the heater assembly air inlet and the heater assembly air outlet. In the embodiment shown, the device air outlet 514 comprises the heater assembly air outlet.

[0124] The apparatus 510 further comprises a spring element 516. The spring element 516 is fixed relative to the outer casing 517 and is in contact with the heater assembly 500.

[0125] FIG. 6 shows a schematic cross-sectional view of an aerosol generation system, which comprises an aerosol generation device as described with reference to FIG. 5 and a cartridge coupled to the aerosol generation device.

[0126] Cartridge 660 is connected to device 610 by cartridge connection 618. Cartridge 660 comprises a liquid aerosol-forming substrate 662 in reservoir 661 and a ceramic wicking element 669. In this system, reservoir 661 is in fluid communication with ceramic wicking element 669 such that liquid aerosol-forming substrate 662 can flow from reservoir 661 to wicking element 669. Wicking element 669 comprises a capillary material having a fibrous or porous structure. Wicking element 669 also forms part of the outer surface of cartridge 660.

[0127] The device air outlet 614 is configured to align with the cartridge air inlet 663 when the device 610 is coupled to the cartridge 660. When the device 610 is coupled to the cartridge 660, the device air flow path 619 connects to the cartridge air flow path 668, defining a system air flow path from the device air inlet 613 to the cartridge air outlet 664. The cartridge includes a mouthpiece 665, and the cartridge air outlet 664 is defined within the mouthpiece 665.

[0128] The wicking element 669 is configured to align with an opening in the frame of the heater assembly. In this specific embodiment, when the system includes a heater assembly according to the first embodiment, the opening is approximately 100 mm 2 The wicking element 669 also has a generally square cross-section with approximately the same cross-sectional area so that the wicking element 669 can be easily accommodated by an opening in the frame of the heater assembly. When the cartridge 660 is coupled to the device 610, the distal end of the wicking element contacts the top of the heating element 630.

[0129] The device 610 further comprises a spring element 616. The spring element 616 is fixed relative to an outer casing 617 of the device and is in contact with the heater assembly 600. When a user couples the cartridge 650 to the device 610, the spring element 617 applies a force to the heater assembly 600. The force applied to the heater assembly 600 ensures good contact between the top of the heating element 630 and the wicking element 669.

[0130] During use, a user draws air into the device's air inlet 613 by inhaling on the cartridge's mouthpiece 665. System 650 is an inhalation-activated system in which an inhalation sensor (not shown), which may be a pressure sensor or airflow sensor, is disposed within system 650. Specifically, the inhalation sensor would be in fluid communication with the system's airflow path, preferably disposed within or adjacent to the device's airflow path 619. The inhalation sensor detects the user's inhalation and sends a signal to controller 612, which in turn causes power to be supplied from battery 611 to heating element 630 of the heater assembly via first and second electrical contacts. This causes electricity to flow through heating element 630, thereby resistively heating it. In other embodiments, aerosol generation system 650 may include a button that a user can press to send a signal to controller 612 to power heating element 630 from battery 611.

[0131] When the heating element 630 is heated, it heats the wicking element 669, and therefore any aerosol-forming substrate 662 contained in the wicking element 669. The heating of the wicking element 669 causes the aerosol-forming substrate 662 to vaporize.

[0132] When a user draws on the cartridge air outlet 664, air is drawn into the device air inlet 613. As the air is drawn through the air passageway, it passes through the heater assembly. The air flows underneath the heating element 630, over the surface of the wicking element 669, and toward the cartridge air outlet 664. Vaporized aerosol-forming substrate 662 becomes entrained in this airflow. This entrained vapor then cools and condenses to form an aerosol. The aerosol exits the device air flow path 619 through the air outlet 614. The aerosol then enters the cartridge 660 through the cartridge air inlet 663, exits the cartridge 660 through the cartridge air outlet 664, and is delivered to the user's mouth.

[0133] As the liquid aerosol-forming substrate 662 in the wicking element 669 is heated, vaporized, and entrained in the airflow, the liquid aerosol-forming substrate 662 from the reservoir 661 migrates into the wicking element 669. This aerosol-forming substrate 662 from the reservoir 661 effectively replaces the vaporized aerosol-forming substrate 662. Because the wicking element 669 is a capillary material having a fibrous or porous structure, the liquid aerosol-forming substrate 662 from the reservoir 661 can be drawn into the wicking element 669 at least partially by capillary action.

[0134] After many uses of the aerosol-generating system 650, the wicking element 669 may begin to deteriorate or the aerosol-forming substrate 662 of the reservoir 661 may become empty. The user can then remove the cartridge 660 from the device 610. The cartridge 660 can be removed and discarded. The aerosol-generating device 610 can then be reused with a new cartridge.

[0135] FIG. 7 shows a cross-sectional schematic view of a cartridge 760 according to another embodiment, the cartridge 760 including a heater assembly 700 according to any of the embodiments described with reference to FIGS. 1A-4B.

[0136] 6, the cartridge 760 shown in FIG. 7 comprises a liquid aerosol-forming substrate 762 within a reservoir 761 and a ceramic wicking element 769. In this system, the reservoir 761 is in fluid communication with the ceramic wicking element 769 such that the liquid aerosol-forming substrate 662 can flow from the reservoir 661 to the wicking element 669. The cartridge further comprises a mouthpiece 765, and an air outlet 764 of the cartridge is defined within the mouthpiece 765.

[0137] 5 and 6, the heater assembly 700 is disposed within the cartridge 760 rather than the aerosol generating device. The heater assembly 700 is positioned such that the wicking element 769 is aligned with an opening in the frame of the heater assembly 700 and such that the distal end of the wicking element 769 contacts the top of the heating element 730. Additionally, the cartridge includes a cartridge air inlet 763 upstream of the heater assembly 700 such that a cartridge air flow path 768 is defined between the cartridge air inlet 763 and the cartridge air outlet 764, and the heating element 730 is in fluid communication with the cartridge air flow path 768.

[0138] The cartridge 760 is configured to connect to a suitable aerosol generating device, the device including a battery, e.g., a lithium iron phosphate battery, a controller electrically connected to the battery, first and second device electrical contact portions, and a cartridge connection portion provided with a space in which the cartridge 760 can be accommodated.

[0139] The cartridge 760 includes first and second cartridge electrical contacts (not shown) configured to contact first and second device electrical contacts when the cartridge 760 is coupled to a suitable device so that power can be supplied from the battery to the heating element 730.

[0140] 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 disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Accordingly, 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 measurement of the property that the number A modifies. In some instances, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. A heater assembly for an aerosol generating device, the heater assembly comprising: a heating element, the heating element comprising a plurality of heating portions and at least one mounting portion; a support structure having a support structure opening and an upper support structure surface parallel to the first plane; a frame, the frame at least partially surrounding the support structure; and a first electrical contact in electrical contact with a first end of the heating element; a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact; the heating element is secured to the frame, each heating section being within or above the support structure opening and separated from the frame by at least one mounting section; each mounting portion comprises a first section and a second section, each first section being substantially parallel to the first plane, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface; both the first and second electrical contacts include a first electrical contact section and a second electrical contact section; A heater assembly, wherein both first electrical contact sections are substantially parallel to said first plane and both second electrical contact sections extend from said upper support structure surface toward said second plane.

2. The heater assembly of claim 1 , wherein each second section extends in a direction perpendicular to the upper support structure surface.

3. 3. The heater assembly of claim 1, wherein at least a portion of the heating element is flush with the upper support structure surface.

4. The heater assembly of claim 3 , wherein the plurality of heating sections are flush with the upper support structure surface.

5. A heater assembly according to any preceding claim, wherein each second section is secured between the frame and the support structure.

6. The heater assembly according to any one of claims 1 to 5, wherein the plurality of heating portions and the at least one mounting portion are all integrally formed.

7. 7. The heater assembly of claim 1, wherein when the direction of the continuous electrical path is defined by each heating portion, each heating portion has a first width in a first direction perpendicular to the direction of the continuous electrical path, and each mounting portion has a second width in the first direction, the second width being greater than the first width.

8. A heater assembly according to any preceding claim, wherein the frame is electrically insulating.

9. 9. The heater assembly of claim 8, wherein the frame has a thermal conductivity of 1 W / mK or less.

10. 10. The heater assembly of any one of claims 1 to 9, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the plurality of heating portions rises above the temperature of the at least one mounting portion.

11. The heater assembly of any preceding claim, wherein the heating element is serpentine-shaped.

12. 1. An aerosol generating device, comprising: a heater assembly, the heater assembly comprising: a heating element, the heating element comprising a plurality of heating portions and at least one mounting portion; a support structure having a support structure opening and an upper support structure surface parallel to the first plane; a frame, the frame at least partially surrounding the support structure; and a first electrical contact in electrical contact with a first end of the heating element; a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact; the heating element is secured to the frame, each heating section being within or above the support structure opening and separated from the frame by at least one mounting section; each mounting portion comprises a first section and a second section, each first section being substantially parallel to the first plane, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface; both the first and second electrical contacts include a first electrical contact section and a second electrical contact section; a heater assembly, wherein both first electrical contact sections are substantially parallel to the first plane and both second electrical contact sections extend from the upper support structure surface toward the second plane; an air flow path defined between an air inlet and an air outlet, the air flow path being in fluid communication with the heating element; a power supply in electrical contact with the first and second electrical contacts and configured to supply power to the heating element; An aerosol generating device comprising: a control circuit configured to control the supply of power from the power source to the heating element.

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

1. A heater assembly, comprising: a heating element, the heating element comprising a plurality of heating portions and at least one mounting portion; a support structure having a support structure opening and an upper support structure surface parallel to the first plane; a frame, the frame at least partially surrounding the support structure; and a first electrical contact in electrical contact with a first end of the heating element; a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact; the heating element is secured to the frame, each heating section being within or above the support structure opening and separated from the frame by at least one mounting section; a heater assembly, wherein each mounting portion comprises a first section and a second section, each first section being substantially parallel to the first plane, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface; an air flow path defined between an air inlet and an air outlet, the air flow path being in fluid communication with the heating element; a power supply in electrical contact with the first and second electrical contacts and configured to supply power to the heating element; a control circuit configured to control the supply of power from the power source to the heating element; and An aerosol generation system, wherein the cartridge is reversibly connectable to the aerosol generation device such that the wicking material is in direct contact with the heating element when the cartridge is coupled to the device.

14. 1. A cartridge for an aerosol generation system, said cartridge comprising: an aerosol-forming substrate in fluid communication with the wicking material; 1. A heater assembly, comprising: a heating element, the wicking material being in contact with the heating element, the heating element comprising a plurality of heating portions and at least one attachment portion; a support structure having a support structure opening and an upper support structure surface parallel to the first plane; a frame, the frame at least partially surrounding the support structure; and a first electrical contact in electrical contact with a first end of the heating element; a second electrical contact in electrical contact with a second end of the heating element, the heating element providing a continuous electrical path between the first electrical contact and the second electrical contact; the heating element is secured to the frame, each heating section being within or above the support structure opening and separated from the frame by at least one mounting section; each mounting portion comprises a first section and a second section, each first section being substantially parallel to the first plane, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface; both the first and second electrical contacts include a first electrical contact section and a second electrical contact section; a heater assembly, wherein both first electrical contact sections are substantially parallel to the first plane and both second electrical contact sections extend from the upper support structure surface toward the second plane.

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