Cartridge with compact internal activation unit

Abstract

The present invention relates to a cartridge for use in an aerosol generating device. The cartridge comprises a longitudinal axis extending between a proximal end and a distal end of the cartridge, an internal airflow path extending between the proximal and distal ends, a liquid reservoir for holding a liquid aerosol-forming substrate, and a tubular internal unit surrounding at least a portion of the internal airflow path. The internal unit comprises a proximal tubular sealing component, an intermediate tubular heater component comprising a susceptor element, and a distal tubular airflow management component. The sealing component, heater component, and airflow management component are connected in series along the longitudinal axis. The present invention also relates to an aerosol generating system.

Description

[Technical Field]

[0001] The present disclosure relates to a cartridge for use with an aerosol generating device. The present disclosure further relates to an aerosol generating system comprising a cartridge and an aerosol generating device. [Background technology]

[0002] It is known to provide an aerosol-generating device for producing an inhalable vapor. Such a device may heat an aerosol-forming substrate contained in a cartridge without burning the aerosol-forming substrate. The aerosol-generating device may include a heating arrangement. The heating arrangement may be an induction heating arrangement and may include an induction coil and a susceptor. The susceptor may be part of the device or part of the cartridge.

[0003] Upon heating to a target temperature, the aerosol-forming substrate vaporizes to form an aerosol. The aerosol-forming substrate may be present in solid or liquid form. The liquid aerosol-forming substrate may be contained within a liquid reservoir or delivered to the heating element via a capillary component. Summary of the Invention [Problem to be solved by the invention]

[0004] Aerosol generating devices and cartridges for use therewith may be taken by consumers wherever they go, and small size devices and cartridges are often preferred to increase portability.

[0005] It would be desirable to provide a cartridge with a compact design.It would be desirable to provide an aerosol generating device with a compact design.It would be desirable to provide an aerosol generating system with a compact design.

[0006] It would be desirable to provide a cartridge for an aerosol generating device that may reduce or avoid leakage of the aerosol-forming substrate. It would be desirable to provide a cartridge for an aerosol generating device that may reduce or avoid leakage of the aerosol-forming substrate during transport. It would be desirable to provide a cartridge for an aerosol generating device that makes it possible to prevent or reduce oxidation of the aerosol-forming substrate of the cartridge before first use. It would be desirable to provide a cartridge for an aerosol generating device that makes it possible to prevent or reduce oxidation of the heating element of the cartridge before first use. It would be desirable to provide a cartridge for an aerosol generating device that may provide a longer shelf life. It would be desirable to provide a cartridge for an aerosol generating device that makes it possible to prevent or reduce water uptake in the cartridge. It would be desirable to provide a cartridge for an aerosol generating device that may improve the user experience. It would be desirable to provide a cartridge for an aerosol generating device that may be more comfortably handled by the user. [Brief explanation of the drawings]

[0007] [Figure 1] Figures 1a to 1c show a tubular inner unit of a cartridge for use with an aerosol generating device. [Figure 2] Figures 2a and 2b show a cartridge for use with an aerosol generating device. [Figure 3] Figures 3a and 3b show a cartridge for use with an aerosol generating device. [Figure 4] 4a and 4b show an aerosol generation system. [Figure 5] 5a and 5b show a heater component of a cartridge for use with an aerosol generating device. [Figure 6]6a and 6b show heater and airflow management components of a cartridge for use with an aerosol generating device. DETAILED DESCRIPTION OF THE INVENTION

[0008] According to an embodiment of the present invention, there is provided a cartridge for use with an aerosol generating device. The cartridge may have a longitudinal axis extending between a proximal end and a distal end of the cartridge. The cartridge may have an internal airflow path extending between the proximal end and the distal end. The cartridge may have a liquid reservoir for holding a liquid aerosol-forming substrate. The cartridge may have a tubular internal unit. The internal unit may surround at least a portion of the internal airflow path. The internal unit may have a proximal tubular sealing component. The internal unit may have an intermediate tubular heater component. The heater component may have a susceptor element. The internal unit may have a distal tubular airflow management component. The sealing component, heater component, and airflow management component may be connected in series along the longitudinal axis.

[0009] According to an embodiment of the present invention, there is provided a cartridge for use with an aerosol generating device. The cartridge has a longitudinal axis extending between a proximal end and a distal end of the cartridge. The cartridge has an internal airflow path extending between the proximal end and the distal end. The cartridge has a liquid reservoir for holding a liquid aerosol-forming substrate. The cartridge has a tubular internal unit surrounding at least a portion of the internal airflow path. The internal unit includes a proximal tubular sealing component, an intermediate tubular heater component including a susceptor element, and a distal tubular airflow management component. The sealing component, heater component, and airflow management component are connected in series along the longitudinal axis.

[0010] The internal unit may provide a cartridge with a compact internal activation unit. A cartridge with a compact design is provided. A cartridge is provided that may reduce or avoid leakage of the aerosol-forming substrate. A cartridge is provided that may make it possible to prevent or reduce oxidation of the heating element of the cartridge prior to first use. A cartridge is provided that may make it possible to prevent or reduce oxidation of the aerosol-forming substrate of the cartridge prior to first use. A cartridge is provided that may provide a longer shelf life. A cartridge is provided that may make it possible to prevent or reduce water uptake in the cartridge. A cartridge is provided that may make it possible to prevent or reduce water uptake in the aerosol-forming substrate. A cartridge is provided that may improve the user experience. A cartridge is provided that may be more comfortably handled by the user.

[0011] The heater component and the airflow management component may be reversibly connected in series along the longitudinal axis. The heater component and the airflow management component may be irreversibly connected in series along the longitudinal axis. The heater component and the airflow management component may be formed as a single piece, e.g., a monolithic piece. The sealing component, the heater component, and the airflow management component may be reversibly connected in series along the longitudinal axis. The sealing component, the heater component, and the airflow management component may be irreversibly connected in series along the longitudinal axis. The sealing component, the heater component, and the airflow management component may be formed as a single piece, e.g., a monolithic piece. As used herein, the term "connected components" may also encompass embodiments in which the connected components are formed as a single piece.

[0012] The internal unit may coaxially surround at least a portion of the internal airflow path.

[0013] A distal end of the heater component may be connected to a proximal end of the airflow management component.A proximal end of the heater component may be connected to a distal end of the sealing component.

[0014] The sealing components, heater components, and airflow management components may be connected by plug connections. A simple way of assembling the internal unit may be provided by plugging the sealing components, heater components, and airflow management components into each other.

[0015] The cartridge may include a tubular sleeve element surrounding at least a portion of the internal unit. The tubular sleeve element may coaxially surround at least a portion of the internal unit. The cartridge may include a liquid supply channel. The liquid supply channel may be disposed between the internal unit and the sleeve element. The liquid supply channel may be configured to supply liquid from a liquid storage portion toward the susceptor element.

[0016] The liquid reservoir may surround a portion of the internal airflow path. The liquid reservoir may coaxially surround a portion of the internal airflow path. The liquid reservoir may be provided proximal to the internal unit with respect to the longitudinal axis of the cartridge. The liquid reservoir may be provided proximal to the sleeve element with respect to the longitudinal axis of the cartridge.

[0017] The cartridge may include a mouthpiece. A proximal end portion of the cartridge may be configured as a mouthpiece. The liquid reservoir may be at least partially disposed within the mouthpiece. The liquid reservoir may form part of the mouthpiece. A distal end of the mouthpiece may be attached to the proximal end of the sleeve element. The distal end of the mouthpiece may be permanently attached to the proximal end of the sleeve element. The distal end of the mouthpiece may be attached to the proximal end of the sleeve element by a mechanical connection, for example, a friction fit or a threaded connection. The distal end of the mouthpiece may be attached to the proximal end of the sleeve element by glue. The distal end of the mouthpiece may be attached to the proximal end of the sleeve element by welding, for example, by laser welding or ultrasonic welding. The distal end of the mouthpiece may be attached to the proximal end of the sleeve element by ultrasonic welding.

[0018] The inner unit may be axially movable relative to the sleeve element.

[0019] The sealing component may comprise a tubular element surrounding a portion of the internal airflow path and a proximal sealing element disposed on an outer surface of the tubular element. The tubular element of the sealing component may coaxially surround a portion of the internal airflow path.

[0020] The proximal sealing element may be provided as a continuous projection circumferentially disposed around the tubular element of the sealing component.

[0021] The proximal sealing element may be provided as a sealing lip. The sealing lip may comprise a hook-like profile.

[0022] The proximal sealing element may be provided as an O-ring. The tubular element may include guiding means to hold the O-ring in place. The O-ring may exhibit a compression ratio of 15 to 25 percent, preferably 18 to 22 percent, and more preferably about 20 percent when the inner unit is in the shut-off position.

[0023] The proximal sealing element may comprise a polymeric material, preferably an elastomeric material. The elastomeric material may be selected from one or more of polytetrafluoroethylene (PTFE), nitrile, neoprene, ethylene propylene diene monomer rubber (EPDM rubber), fluorocarbon, silicone, low-density polyethylene (LDPE), and polypropylene (PP). The elastomeric material may comprise a soft polymer, such as one or both of LDPE and PP. The elastomeric material may comprise a thermoplastic elastomer (TPE). The TPE may have a hardness of 30 to 90 Shore A.

[0024] The tubular element and the proximal sealing element of the sealing component may be made from the same material.The tubular element and the proximal sealing element of the sealing component may be constructed as a monolithic piece.

[0025] The internal unit may be axially movable relative to the sleeve element from a blocking position to an open position. In the blocking position, the proximal sealing element may be arranged to block the fluid connection between the liquid storage portion and the liquid supply channel. In the open position, the proximal sealing element may be moved to open the fluid connection between the liquid storage portion and the liquid supply channel.

[0026] The shut-off position may be the pre-use configuration of an unused cartridge.

[0027] In the shut-off position, the liquid reservoir may be sealed by the proximal sealing element. Leakage of the aerosol-forming substrate may be further reduced or avoided. Exposure of the aerosol-forming substrate to oxygen may be further reduced or avoided. Exposure of the aerosol-forming substrate to high humidity may be further reduced or avoided. A cartridge is provided that may offer a longer shelf life.

[0028] In the blocked position, the susceptor element may be fluidly isolated from the liquid aerosol-forming substrate in the liquid reservoir by the proximal sealing element, and oxidation of the susceptor element of the cartridge prior to first use may be further reduced or prevented prior to first use of the cartridge.

[0029] In the blocked position, the proximal sealing element may contact an internal wall of the cartridge to block the fluid connection between the liquid storage portion and the liquid supply channel. In the open position, the proximal sealing element may move away from the internal wall of the cartridge to open the fluid connection between the liquid storage portion and the liquid supply channel. The internal wall of the cartridge may be an internal wall of the sleeve element. The internal wall of the cartridge may be an internal wall of the mouthpiece.

[0030] The cartridge may be configured to automatically move the internal unit from the closed position to the open position upon engagement of the cartridge with the aerosol generating device, whereby the cartridge may be handled comfortably by the user.

[0031] The cartridge may comprise a pushing means provided at a distal end of the cartridge. The pushing means may be directly connected to the internal unit. The pushing means may be part of the internal unit. The pushing means may be part of a distal end face of the airflow management component. The cartridge may be configured such that, upon engagement of the cartridge with the aerosol generation device, pushing the pushing means towards the proximal end of the cartridge moves the internal unit from the closed position to the open position.

[0032] The cartridge may be configured such that the internal unit remains in an open position when the cartridge is removed from the aerosol generating device, which may allow a user to easily visually verify whether the cartridge is an unused cartridge or a used cartridge.

[0033] The internal unit may remain connected to the remainder of the cartridge in both the closed and open positions.

[0034] The heater component may include a fluid-permeable wall portion arranged to allow movement of the liquid aerosol-forming substrate from the liquid supply channel to the internal airflow path. The fluid-permeable wall portion may be arranged to allow movement of the liquid aerosol-forming substrate toward the susceptor element in the internal airflow path. The fluid-permeable wall portion may be a porous or perforated wall portion. The fluid-permeable wall portion may be formed by two slits in opposite side walls of the tubular heater component. The susceptor element may be located in the internal airflow path between the two slits.

[0035] The cartridge may include a wick element arranged to transport the liquid aerosol-forming substrate from the liquid feed channel toward the susceptor element. The cartridge may include a wick element arranged to transport the liquid aerosol-forming substrate from the liquid feed channel to the susceptor element. The heater component may include a wick element. The wick element may include one or more of a cotton-based material, a porous ceramic-based material, a porous graphite-based material, and a glass fiber sheet material.

[0036] The fluid permeable wall portion of the heater component may be formed by two slits in opposing side walls of the tubular heater component, and the wick element may extend between and through the slits.

[0037] The central portion of the core element may be disposed within the internal airflow path and may be located immediately adjacent, and preferably in physical contact with, the susceptor element. The susceptor element may comprise a substantially planar portion located immediately adjacent, and preferably in physical contact with, the substantially planar portion of the core element. The susceptor element may comprise a single layer. The susceptor element may comprise two or more layers.

[0038] The central portion of the core element may be disposed within the internal airflow path and may be sandwiched by the susceptor element. The susceptor element may comprise two substantially planar portions sandwiching the core element. Each of the two substantially planar portions may be a single layer of material or may include two or more layers of material. The susceptor elements sandwiching the core element may describe a U-shape. The core element may have a sheet-like shape.

[0039] The fluid permeable wall portion of the heater component may be formed by two slits in opposing side walls of the tubular heater component, and the wick element may extend between and through the slits, and a central portion of the wick element may be disposed within the internal airflow path and may be sandwiched by susceptor elements, and the susceptor elements sandwiching the wick element may describe a U-shape and may comprise two substantially planar portions sandwiching the wick element, and the wick element may have a sheet-like shape.

[0040] The airflow management component may comprise a tubular element surrounding a portion of the internal airflow path and a retention element provided at a distal end of the airflow management component, which may help to reduce or prevent leakage of the liquid aerosol-forming substrate or liquid condensate.

[0041] The tubular element of the airflow management component may be a tubular sidewall. The tubular element of the airflow management component may coaxially surround a portion of the internal airflow path.

[0042] The retaining element may comprise a closed distal end wall of the airflow management component. Such a closed distal end wall may provide the retaining element with a particularly good fit for receiving the liquid aerosol-forming substrate from one or both of the susceptor element and the cartridge's internal airflow path. The retaining element may be shaped as a trough. This may allow the retaining element to collect and receive a larger amount of the liquid aerosol-forming substrate.

[0043] The tubular sidewall of the airflow management component may include at least one air inlet for providing air into the internal airflow path, and the at least one air inlet may be located spaced apart from the distal end of the airflow management component.

[0044] The airflow management component may comprise an airflow directing element disposed within the internal airflow path. The airflow directing element may be configured to direct airflow across the susceptor element. The airflow directing element may comprise a divider wall element extending between opposing wall portions of the tubular sidewall of the airflow management component.

[0045] The airflow management component may include a distal sealing element disposed on an outer surface of the tubular element or on a tubular sidewall of the airflow management component. The distal sealing element may be configured to seal a distal end of the liquid feed channel.

[0046] The distal portion of the cartridge may have a circular cross-section perpendicular to the longitudinal axis of the cartridge. The proximal portion of the cartridge may have an oval cross-section perpendicular to the longitudinal axis of the cartridge. The oval cross-section may taper toward the proximal end.

[0047] The distal end portion of the cartridge may be configured to engage with an aerosol generating device. The distal end portion of the cartridge may be configured to be inserted into a cavity of the aerosol generating device. The distal end portion of the cartridge may comprise connecting means configured to be releasably connectable to the aerosol generating device. The connecting means may be mechanical. The connecting means may comprise one or more springs. The one or more springs may be made of a plastic material, a metal material, or a combination thereof. The connecting means may comprise magnetic connecting means.

[0048] The distal end of the cartridge may be configured to engage with an aerosol generating device. The distal end of the cartridge may be configured to be inserted into a cavity of the aerosol generating device. The distal end of the cartridge may comprise a connecting means configured to be releasably connectable to the aerosol generating device. The connecting means may be mechanical. The connecting means may comprise one or more springs. The one or more springs may be made of a plastic material, a metal material, or a combination thereof. The connecting means may comprise a magnetic connecting means.

[0049] The proximal end of the cartridge may be a mouth end. The proximal end of the cartridge may comprise a mouthpiece. The proximal end of the cartridge may comprise an air outlet.

[0050] According to an embodiment of the present invention, there is provided an aerosol generation system comprising a cartridge as described herein and an aerosol generation device. The aerosol generation device comprises a cavity arranged to receive at least a distal portion of the cartridge. The aerosol generation device comprises one or more inductor coils. The cavity is at least partially surrounded by the one or more inductor coils. The cavity may be at least partially coaxially surrounded by the one or more inductor coils. An aerosol generation system having a compact design is provided.

[0051] The aerosol generating device may include a pin element. The pin element may protrude from a distal end face of the cavity. The pin element may be a spring-loaded pin. The pin element may be a rigid pin. The pin element may be arranged to press against a distal end of the cartridge when the cartridge is inserted into the cavity. The pin element may be arranged to press against a distal end of an internal unit of the cartridge when the cartridge is inserted into the cavity. This may allow the internal unit of the cartridge to move axially relative to the sleeve element to open the liquid supply channel for fluid connection between the liquid storage portion and the liquid supply channel. The pin element may be arranged to press a proximal sealing element of the internal unit from a closed position to an open position when the cartridge is inserted into the cavity.

[0052] When a new cartridge is purchased, the distal end of the internal unit of the new cartridge may protrude from the sleeve element of the cartridge. In this position, the internal unit may be in a blocking position with respect to the sleeve element. This may block the fluid connection between the liquid storage portion and the liquid supply channel before use and before the cartridge is inserted into the cavity of the aerosol generating device.

[0053] The cavity of the aerosol generating device may be a heated chamber.

[0054] As used herein, the terms "tubular," "tubular unit," "tubular component," "tubular element," and "tubular shape" refer to a three-dimensional object and geometric shape that includes a bottom basal plane, a top basal plane, and a sidewall that encloses a hollow interior, the sidewall being disposed between the bottom and top basal planes. The sidewall extends along a longitudinal axis of the tubular element between the bottom and top basal planes. The longitudinal axis may be perpendicular to one or both of the bottom and top basal planes.

[0055] The bottom base of the tubular element lies in a bottom base plane. The top base of the tubular element lies in a top base plane. The cross-sectional shape of one or both of the bottom and top bases may be circular. The cross-sectional shape of one or both of the bottom and top bases may be non-circular, for example, elliptical, stadium-shaped, or rectangular. One or both of the bottom and top bases may be open.

[0056] The tubular element may have the shape of a right circular hollow cylinder. The tubular element may have the shape of a non-circular hollow cylinder, for example an elliptical hollow cylinder or a stadium-shaped hollow cylinder. The tubular element may have the shape of a hollow rectangular parallelepiped.

[0057] The longitudinal axis of the tubular element may be disposed parallel to the longitudinal axis of the cartridge. The central longitudinal axis of the tubular element may be coincident with the central longitudinal axis of the cartridge.

[0058] One or more of the sealing component, heater component, and airflow management component may have a non-circular cross-section perpendicular to the longitudinal axis of the tubular inner unit. One or more of the sealing component, heater component, and airflow management component may have a non-circular cross-section perpendicular to the longitudinal axis of the cartridge. One or more of the sealing component, heater component, and airflow management component may have a stadium-shaped cross-section perpendicular to the longitudinal axis of the tubular inner unit. One or more of the sealing component, heater component, and airflow management component may have a stadium-shaped cross-section perpendicular to the longitudinal axis of the cartridge.

[0059] The heater and airflow management components may have a non-circular cross-section perpendicular to the longitudinal axis of one or both of the tubular inner unit and cartridge.The heater and airflow management components may have a stadium-shaped cross-section perpendicular to the longitudinal axis of one or both of the tubular inner unit and cartridge.

[0060] The sealing components, heater components, and airflow management components may have non-circular cross-sections perpendicular to the longitudinal axis of one or both of the tubular inner unit and cartridge. The sealing components, heater components, and airflow management components may have stadium-shaped cross-sections perpendicular to the longitudinal axis of one or both of the tubular inner unit and cartridge.

[0061] As used herein, the term "aerosol-forming substrate" relates to a substrate capable of releasing volatile compounds that can form an aerosol or vapor. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may also be in liquid form. The terms "aerosol" and "vapor" are used interchangeably.

[0062] The aerosol-forming substrate may be part of a cartridge. The aerosol-forming substrate may be part of a liquid held in a liquid reservoir of the cartridge. The liquid reservoir may contain the liquid aerosol-forming substrate.

[0063] Preferably, a liquid nicotine or flavor / flavorant-containing aerosol-forming substrate may be employed within the liquid reservoir portion of the cartridge.

[0064] The aerosol-forming substrate may comprise nicotine.

[0065] The aerosol-forming substrate may include at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense, stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the device. 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). Preferred aerosol formers are polyhydric alcohols or mixtures thereof (e.g., triethylene glycol, 1,3-butanediol, etc.). Preferably, the aerosol former is glycerin.

[0066] As used herein, the term "cartridge" refers to an article comprising an aerosol-forming substrate capable of emitting a volatile compound capable of forming an aerosol. For example, a cartridge may be an article that generates an aerosol that is inhalable by a user sucking or puffing on a mouthpiece at the proximal or user end of the device, or directly at the mouthpiece of the cartridge itself. A cartridge may be disposable. A cartridge may be reusable. A cartridge may be refillable. A cartridge may be insertable into a cavity of an aerosol-generating device.

[0067] As used herein, the term "liquid reservoir" refers to a reservoir containing an aerosol-forming substrate capable of emitting a volatile compound capable of forming an aerosol. The liquid reservoir may be configured as a container or reservoir for storing the liquid aerosol-forming substrate.

[0068] The liquid reservoir may be configured as a replaceable tank or container. The liquid reservoir may be of any suitable shape and size. For example, the liquid reservoir may be substantially cylindrical. The cross section of the liquid reservoir may be, for example, substantially circular, oval, square, or rectangular. The liquid reservoir may form part of a cartridge.

[0069] As used herein, the term "aerosol generating device" refers to a device that interacts with a cartridge to generate an aerosol.

[0070] As used herein, the term "aerosol generation system" refers to the combination of an aerosol generator with a cartridge, in which the aerosol generator and cartridge work together to generate a respirable aerosol.

[0071] The aerosol generating device is preferably portable. The aerosol generating device may have a size comparable to a conventional cigar or cigarette. The device may be an electrically operated smoking device. The device may be a handheld aerosol generating device. The aerosol generating device may have a total length of 30 mm to 150 mm. The aerosol generating device may have an outer diameter of 5 mm to 30 mm.

[0072] The aerosol generating device may include a housing. The housing may be elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene. Preferably, the material is lightweight and not brittle.

[0073] The housing may include at least one air inlet. The housing may include two or more air inlets.

[0074] The aerosol generating device may comprise a heating element, which may comprise at least one inductor coil for inductively heating one or more susceptors.

[0075] Operation of the heating element may be triggered by a puff detection system. Alternatively, the heating element may be triggered by pressing an on / off button and maintained for the duration of the user's puff. The puff detection system may be provided as a sensor, which may be configured as an airflow sensor for measuring airflow velocity. Airflow velocity is a parameter that characterizes the amount of air per time drawn by the user through the airflow path of the aerosol generating device. The onset of a puff may be detected by the airflow sensor when the airflow exceeds a predetermined threshold. The onset may also be detected when the user activates a button. The sensor may also be configured as a pressure sensor.

[0076] The aerosol-generating device may include a user interface for activating the aerosol-generating device, such as a button to initiate heating of the aerosol-generating device, or a display that indicates the status of the aerosol-generating device or aerosol-forming substrate.

[0077] The aerosol generating device may include additional components, such as, for example, a charging unit for recharging an on-board power supply within an electrically operated or electric aerosol generating device.

[0078] As used herein, the term "proximal" refers to the user end or mouth end of a cartridge or aerosol generation device or system, or part or portions thereof, and the term "distal" refers to the end opposite the proximal end. When referring to a cavity or heating chamber, the term "proximal" refers to the area nearest the open end of the cavity, and the term "distal" refers to the area nearest the closed end.

[0079] As used herein, the terms "upstream" and "downstream" are used to describe the relative location of components or portions of components of an aerosol generating device with respect to the direction in which a user draws on the aerosol generating device during use.

[0080] As used herein, the term "airflow path" means a channel suitable for transporting a gaseous medium. The airflow path may be used to transport ambient air. The airflow path may be used to transport an aerosol. The airflow path may be used to transport a mixture of air and an aerosol.

[0081] As used herein, "susceptor" or "susceptor element" means an element that heats when subjected to an alternating magnetic field. This may be the result of eddy currents induced in the susceptor element, hysteresis losses, or both eddy currents and hysteresis losses. During use, the susceptor element is positioned in thermal contact or thermal proximity with an aerosol-forming substrate received in an aerosol-generating device or cartridge. In this manner, the aerosol-forming substrate is heated by the susceptor, thereby forming an aerosol.

[0082] The susceptor material may be any material that can be inductively heated to a temperature sufficient to aerosolize the aerosol-forming substrate. The following examples and features regarding susceptors may also be applied to the susceptor element of the cartridge. Suitable materials for the susceptor material include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Preferred susceptor materials include metal or carbon. Advantageously, the susceptor material may include or consist of ferromagnetic or ferrimagnetic materials, such as ferritic iron, ferromagnetic steel, or stainless steel, ferromagnetic particles, and ferrite. A suitable susceptor material may be or include aluminum. The susceptor material may include more than 5 percent, preferably more than 20 percent, more preferably more than 50 percent, or more than 90 percent ferromagnetic, ferrimagnetic, or paramagnetic material. Preferred susceptor materials may be heated to temperatures in excess of 250 degrees Celsius without degradation.

[0083] The susceptor material may be formed from a single layer of material, which may be a steel layer.

[0084] The susceptor material may comprise a non-metallic core having a metallic layer disposed thereon, for example, the susceptor material may comprise a ceramic core or metallic tracks formed on the outer surface of the substrate.

[0085] The susceptor material may be formed from a layer of austenitic steel. One or more layers of stainless steel may be disposed on the layer of austenitic steel. For example, the susceptor material may be formed from a layer of austenitic steel with a layer of stainless steel on each of its upper and lower surfaces. The susceptor element may include a single susceptor material. The susceptor element may include a first susceptor material and a second susceptor material. The first susceptor material may be disposed in intimate physical contact with the second susceptor material. The first susceptor material and the second susceptor material may be in intimate contact to form a single, indestructible susceptor. In one particular embodiment, the first susceptor material is stainless steel and the second susceptor material is nickel. The susceptor element may have a two-layer structure. The susceptor element may be formed from a stainless steel layer and a nickel layer.

[0086] The intimate contact between the first susceptor material and the second susceptor material may be achieved by any suitable means. For example, the second susceptor material may be plated, deposited, coated, clad, or welded onto the first susceptor material. Preferred methods include electroplating, galvanizing, and cladding.

[0087] The aerosol generating device may include a power source to power the heating element. The power source may include a battery. The power source may be a lithium-ion battery. Alternatively, the power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery (e.g., a lithium-cobalt battery, a lithium-iron-phosphate battery, a lithium-titanate battery, or a lithium-polymer battery). The power source may require recharging and may have a capacity that allows for storage of sufficient energy for one or more use experiences; for example, the power source may have a capacity sufficient to continuously generate aerosol for a period of approximately six minutes, or a multiple of six minutes. In another embodiment, the power source may have a capacity sufficient to provide a predetermined number of puffs or discontinuous activation of the heating element.

[0088] The power source may be a direct current (DC) power source. In one embodiment, the power source is a DC power source having a DC supply voltage in the range of 2.5 volts to 4.5 volts and a DC supply current in the range of 1 ampere to 10 amperes (corresponding to a DC power range of 2.5 watts to 45 watts). Advantageously, the aerosol generating device may comprise a direct current to alternating current (DC / AC) inverter for converting the DC current provided by the DC power source into alternating current. The DC / AC converter may comprise a class D, class C, or class E power amplifier. The AC power output of the DC / AC converter is provided to the induction coil.

[0089] The power supply may be adapted to supply power to the inductor coil and may be configured to operate at high frequencies. For high frequency operation, a Class E power amplifier is preferred. As used herein, the term "high frequency oscillating current" refers to an oscillating current having a frequency between 500 kilohertz and 30 megahertz. The high frequency oscillating current may have a frequency between 1 megahertz and 30 megahertz, preferably between 1 megahertz and 10 megahertz, and more preferably between 5 megahertz and 8 megahertz.

[0090] In alternative embodiments, the switching frequency of the power amplifier may be in the lower kHz range, for example, 100 kHz to 400 kHz. In embodiments where a class D or class C power amplifier is used, a switching frequency in the lower kHz range is particularly advantageous.

[0091] The aerosol generating device may include a controller. The controller may be electrically connected to the inductor coil. The controller may be electrically connected to the first induction coil and to the second induction coil. The controller may be configured to control the current supplied to the induction coil and therefore the magnetic field strength generated by the induction coil(s).

[0092] A power supply and a controller may be connected to the inductor coil.

[0093] The controller may be configured to chop the current supply on the input side of the DC / AC converter, so that the power supplied to the inductor coil may be controlled by conventional methods of duty cycle management.

[0094] Below is provided a non-exhaustive list of non-limiting examples, any one or more of the features of these examples may be combined with any one or more features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.

[0095] Example E1: A cartridge for use with an aerosol generating device, comprising: a longitudinal axis extending between the proximal and distal ends of the cartridge; an internal airflow pathway extending between the proximal end and the distal end; a liquid reservoir for holding a liquid aerosol-forming substrate; a tubular inner unit surrounding at least a portion of the internal airflow path; the inner unit comprises a proximal tubular sealing component, an intermediate tubular heater component comprising a susceptor element, and a distal tubular airflow management component; and A cartridge in which a sealing component, a heater component, and an airflow management component are connected in series along the longitudinal axis.

[0096] Example E2: A cartridge according to example E1, wherein a distal end of the heater component is connected to a proximal end of the airflow management component, and a proximal end of the heater component is connected to a distal end of the sealing component.

[0097] Example E3: A cartridge according to Example E1 or Example E2, wherein the sealing component, the heater component, and the airflow management component are connected by a plug connection.

[0098] Example E4: A cartridge according to any of the preceding examples, wherein the liquid reservoir surrounds a portion of the internal airflow path.

[0099] Example E5: A cartridge according to any of the preceding examples, comprising a tubular sleeve element surrounding at least a portion of the internal unit, and a liquid supply channel disposed between the internal unit and the sleeve element.

[0100] Embodiment E6: A cartridge according to embodiment E5, wherein the internal unit is axially movable relative to the sleeve element.

[0101] Example E7: The sealing component comprises a tubular element surrounding a portion of the internal airflow path and a proximal sealing element disposed on an outer surface of the tubular element; and A cartridge according to example E6, wherein the internal unit is axially movable relative to the sleeve element from a blocking position in which the proximal sealing element is arranged to block the fluid connection between the liquid storage portion and the liquid supply channel to an open position in which the proximal sealing element moves to open the fluid connection between the liquid storage portion and the liquid supply channel.

[0102] Example E8: A cartridge according to any of Examples E5 to E7, comprising a mouthpiece, wherein the liquid storage portion forms part of the mouthpiece, preferably wherein the distal end of the mouthpiece is attached to the proximal end of the sleeve element, more preferably wherein the distal end of the mouthpiece is attached to the proximal end of the sleeve element by ultrasonic welding.

[0103] Example E9: A cartridge according to any of Examples E5 to E8, wherein the heater component comprises a fluid-permeable wall portion arranged to allow movement of the liquid aerosol-forming substrate from the liquid supply channel to the internal airflow path.

[0104] Example E10: A cartridge according to example E9, wherein the fluid permeable wall portion is formed by two slits in opposing side walls of the tubular heater element.

[0105] Example E11: A cartridge according to example E9 or example E10, comprising a wick element arranged to transfer the liquid aerosol-forming substrate from the liquid feed channel to the susceptor element.

[0106] Example E12: A cartridge according to any of the preceding examples, wherein the airflow management component comprises a tubular sidewall surrounding a portion of the internal airflow path and a retaining element provided at a distal end of the airflow management component, preferably wherein the retaining element comprises a closed distal end wall of the airflow management component.

[0107] Example E13: A cartridge according to example E12, wherein the tubular side wall of the airflow management component has at least one air intake port for providing air into the internal airflow path, preferably the at least one air intake port being located away from the distal end of the airflow management component.

[0108] Example E14: A cartridge according to example E12 or example E13, wherein the airflow management component comprises an airflow directing element disposed within the internal airflow path and wherein the airflow directing element is configured to direct airflow across the susceptor element, preferably wherein the airflow directing element comprises a partition wall element extending between opposing wall portions of the tubular side wall.

[0109] Example E15: A cartridge according to a combination of any of Examples E5 to E11 and any of Examples E12 to E14, wherein the airflow management component comprises a distal sealing element disposed on the outer surface of the tubular side wall, and the distal sealing element is configured to seal the distal end of the liquid supply channel.

[0110] Example E16: An aerosol generating system comprising: a cartridge according to any of the preceding embodiments; An aerosol generation system comprising: an aerosol generation device having a cavity arranged to receive at least a distal portion of a cartridge, the cavity being at least partially surrounded by an inductor coil.

[0111] Example E17: An aerosol-generating system according to Example E16, wherein the cavity is a heating chamber.

[0112] Features described with respect to one embodiment may be equally applied to other embodiments of the invention.

[0113] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:

[0114] 1a shows a tubular inner unit 10 in an exploded configuration. The inner unit 10 comprises a proximal tubular sealing component 20, an intermediate tubular heater component 40 with a susceptor element (not shown) within its hollow interior, and a distal tubular airflow management component 60.

[0115] The sealing component 20 includes a tubular element 22 and a proximal sealing element 24 disposed on an outer surface of the tubular element 22. The proximal sealing element 24 is provided as a continuous protrusion circumferentially disposed around the tubular element 22 of the sealing component 20. The proximal sealing element 24 is provided as a sealing lip. The tubular element 22 and the proximal sealing element 24 of the sealing component 20 are formed as a monolithic piece.

[0116] Airflow management component 60 includes a tubular sidewall 62 and a distal sealing element 64 provided as an O-ring disposed on the outer surface of tubular sidewall 62. The O-ring is held in place axially between first and second protrusions 66, 67 of airflow management component 60.

[0117] FIG. 1b shows the tubular inner unit 10 of FIG. 1a in an assembled configuration. The sealing component 20, heater component 40, and airflow management component 60 are connected in series along the longitudinal axis 12. The connection may be reversible or irreversible. The distal end of the heater component 40 plugs into the proximal end of the airflow management component 60. The proximal end of the heater component 40 plugs into the distal end of the sealing component 20. The plugging action is indicated by an arrow in FIG. 1a. Alternatively, the heater component 40 and airflow management component 60, and optionally the sealing component 20, may be formed as a single piece.

[0118] 1c shows the assembled tubular inner unit 10 of FIG. 1b in cross-section. The airflow management component 60 includes an air inlet 68 that allows air to enter the hollow tubular interior of the tubular inner unit 10. An internal airflow path 14 is surrounded by the tubular inner unit 10. The internal airflow path 14 passes through the susceptor 42 of the heater component 40.

[0119] Figure 2a shows the cartridge 100 in an exploded configuration. The cartridge 100 comprises the inner unit 10 of Figures 1a to 1c. The cartridge 100 comprises a tubular sleeve element 80. The cartridge 100 comprises a mouthpiece 90.

[0120] Figure 2b shows the cartridge 100 of Figure 2a in a cross-sectional view in an assembled configuration. A tubular sleeve element 80 surrounds a portion of the inner unit 10. A liquid supply channel 82 is formed by the empty space between the inner unit 10 and the sleeve element 80. A distal sealing element 64 of the airflow management component 60 is configured to close and seal the distal end of the liquid supply channel 82.

[0121] The mouthpiece 90 includes a liquid reservoir 92 that surrounds a portion of the internal airflow path 14. The liquid reservoir 92 is provided by an empty space between an internal tubular wall portion 96 of the mouthpiece 90 that surrounds the internal airflow path 14 and an external tubular wall portion 98 of the mouthpiece 90 that surrounds the liquid reservoir 92. A proximal end 94 of the mouthpiece 90 includes an air outlet. A distal end 99 of the mouthpiece 90 is attached to the proximal end 84 of the sleeve element 80. For example, permanent attachment may be achieved by ultrasonic welding.

[0122] 3a shows a cartridge 100 that is primarily identical to the cartridge 100 of FIGS. 2a and 2b, except that the air inlet 68 is located in a different position. In the embodiment of FIG. 3a, the air inlet 68 is located within the tubular side wall 62 of the airflow management component 60. The air inlet 68 is therefore located spaced apart from the distal end of the airflow management component 60. The airflow management component 60 thereby comprises a retention element 70 provided at the distal end of the airflow management component 60, the retention element 70 comprising a closed distal end wall of the airflow management component 60.

[0123] The inner unit 10 is axially movable with respect to the sleeve element 80 from a blocking position shown in FIG. 3 a, in which the proximal sealing element 24 is arranged to block the fluid connection between the liquid storage portion 92 and the liquid supply channel 82, to an open position shown in FIG. 3 b, in which the proximal sealing element 24 moves to open the fluid connection between the liquid storage portion 92 and the liquid supply channel 82. In the blocking position shown in FIG. 3 a, the proximal sealing element 24 contacts an inner wall of the sleeve element 80 to block the fluid connection between the liquid storage portion 92 and the liquid supply channel 82.

[0124] In the open position shown in Figure 3b, the proximal sealing element 24 moves away from the interior wall, opening the fluid connection between the liquid storage portion 92 and the liquid supply channel 82. In the open position shown in Figure 3b, a liquid passageway 16 is formed, allowing the liquid aerosol-forming substrate to move from the liquid storage portion 92 into the liquid supply channel 82. The distal sealing element 64 of the airflow management component 60 seals the distal end of the liquid supply channel 82 and prevents the liquid aerosol-forming substrate from exiting the liquid supply channel 82 at its distal end in the open position.

[0125] The distal portion of the inner tubular wall portion 96 of the mouthpiece 90 may slide within the proximal portion of the tubular element 22 of the sealing component 20 when the inner unit 10 moves axially from the blocked position shown in FIG. 3a to the open position shown in FIG. 3b.

[0126] The heater component 40 includes a fluid-permeable wall portion 44 disposed to permit movement of the liquid aerosol-forming substrate from the liquid feed channel 82 into the internal airflow path 14 and toward the susceptor element 42 .

[0127] 4a and 4b show cross-sectional views of an aerosol generation system comprising a cartridge, such as cartridge 100 of FIGS. 2 and 3, and an aerosol generation device 200. The aerosol generation device 200 comprises a heating chamber 210 arranged to receive at least a distal portion of the cartridge 100. The heating chamber 210 is at least partially surrounded by an inductor coil 220.

[0128] The aerosol-generating device 200 includes a pin element 230 protruding from a distal end face of the heating chamber 210. The pin element 230 is arranged to push the inner unit 10 of the cartridge 100 from the closed position to the open position when the distal portion of the cartridge 100 is inserted into the heating chamber 210. Figure 4b shows a configuration in which the distal portion of the cartridge 100 is inserted into the heating chamber 210 and the inner unit 10 is in the open position. As a result, the liquid aerosol-forming substrate may move toward the susceptor 42.

[0129] Furthermore, as shown in FIG. 4b, when the distal portion of the cartridge 100 is inserted into the heating chamber 210, the susceptor 42 of the cartridge 100 is positioned within the heating chamber 210, whereby the alternating current applied to the inductor coil 220 induces a current in the susceptor 42, creating an alternating magnetic field that heats the susceptor 42.

[0130] Ambient air may enter the aerosol generation system via a gap between the cartridge 100 and the aerosol generation device 200. Alternatively, or additionally, the aerosol generation device 200 may include an air inlet (not shown) in fluid communication with the heating chamber 210.

[0131] Airflow path 240 is shown as a dotted line in Figure 4b. A liquid aerosol-forming substrate located in proximity to or in contact with the heated susceptor 42 may volatilize due to the high temperature in the area of the susceptor 42. The volatilized material may be entrained by the airflow and may travel downstream along airflow path 240 and through the air outlet at the proximal end 94 of the cartridge 100, where the ripened aerosol may be inhaled by a user.

[0132] The distal end of the cartridge 100 may be provided with a connecting means (not shown), e.g., a magnetic connecting means, configured to be releasably connectable to the aerosol generating device 200. The aerosol generating device 200 may be provided with a corresponding connecting means (not shown).

[0133] 5a and 5b show an embodiment of a heater component 40 in a perspective view (FIG. 4a) and a front view (FIG. 4b). A fluid-permeable wall portion 44 is formed by two slits in opposing sidewalls of the tubular heater component 40. A wick element 46 extends between and through the slits. The wick element 46 is positioned to transfer liquid aerosol-forming substrate from the liquid feed channel 82 to the susceptor element 42 when the heater component 40 is disposed within the sleeve element 80. A central portion of the wick element 46 within the internal airflow path 14 is sandwiched by the susceptor element 42, describing a U-shape.

[0134] Figures 6a and 6b show an alternative embodiment of heater component 40 and airflow management component 60 in an exploded (Figure 6a) and assembled (Figure 6b) configuration. Unlike the embodiment of Figures 1a-1c, in the embodiment of Figures 6a and 6b, a sealing element 64, provided as an O-ring, is held axially in place between a first protrusion 48 that is part of heater component 40 and a second protrusion 67 that is part of airflow management component 60.

Claims

1. 1. A cartridge for use with an aerosol generating device, comprising: a longitudinal axis extending between a proximal end and a distal end of the cartridge; an internal airflow path extending between the proximal end and the distal end; a liquid reservoir for holding a liquid aerosol-forming substrate; a tubular inner unit surrounding at least a portion of the internal airflow path; the tubular inner unit comprises a proximal tubular sealing component, an intermediate tubular heater component comprising a susceptor element, and a distal tubular airflow management component; and A cartridge wherein the sealing component, the heater component, and the airflow management component are connected in series along the longitudinal axis.

2. The cartridge of claim 1 , wherein a distal end of the heater component is connected to a proximal end of the airflow management component, and a proximal end of the heater component is connected to a distal end of the sealing component.

3. 3. The cartridge of claim 1 or claim 2, wherein the sealing component, the heater component, and the airflow management component are connected by a plug connection.

4. The cartridge of any one of claims 1 to 3, wherein the liquid storage portion surrounds a portion of the internal airflow path.

5. 5. The cartridge of claim 1, further comprising a tubular sleeve element surrounding at least a portion of the tubular internal unit, and a liquid supply channel disposed between the tubular internal unit and the sleeve element.

6. The cartridge of claim 5 , wherein the tubular inner unit is axially movable relative to the sleeve element.

7. the sealing component comprises a tubular element surrounding a portion of the internal airflow path and a proximal sealing element disposed on an outer surface of the tubular element; and 7. The cartridge of claim 6, wherein the tubular internal unit is axially movable relative to the sleeve element from a blocking position in which the proximal sealing element is arranged to block the fluid connection between the liquid storage portion and the liquid supply channel to an open position in which the proximal sealing element moves to open the fluid connection between the liquid storage portion and the liquid supply channel.

8. A cartridge according to any one of claims 5 to 7, comprising a mouthpiece, the liquid storage portion forming part of the mouthpiece, preferably a distal end of the mouthpiece being attached to the proximal end of the sleeve element, more preferably the distal end of the mouthpiece being attached to the proximal end of the sleeve element by ultrasonic welding.

9. 9. A cartridge according to claim 5, wherein the heater element comprises a fluid-permeable wall portion arranged to allow movement of a liquid aerosol-forming substrate from the liquid supply channel to the internal airflow path, preferably the fluid-permeable wall portion being formed by two slits in opposite side walls of the tubular heater element.

10. 10. The cartridge of claim 9, comprising a wick element arranged to transport a liquid aerosol-forming substrate from the liquid supply channel to the susceptor element.

11. 11. A cartridge according to any preceding claim, wherein the airflow management component comprises a tubular side wall surrounding a portion of the internal airflow path and a retaining element provided at the distal end of the airflow management component, preferably the retaining element comprising a closed distal end wall of the airflow management component.

12. 12. The cartridge of claim 11, wherein the tubular sidewall of the airflow management component comprises at least one air intake port for providing air into the internal airflow path, preferably the at least one air intake port being located away from the distal end of the airflow management component.

13. 13. A cartridge as described in claim 11 or claim 12, wherein the airflow management component comprises an airflow directing element disposed within the internal airflow path and configured to direct airflow across the susceptor element, preferably wherein the airflow directing element comprises a partition wall element extending between opposing wall portions of the tubular side wall.

14. A cartridge described in combination of any one of claims 5 to 10 and any one of claims 11 to 13, wherein the airflow management component comprises a distal sealing element disposed on an outer surface of the tubular side wall, and the distal sealing element is configured to seal the distal end of the liquid supply channel.

15. 1. An aerosol generating system comprising: A cartridge according to any one of claims 1 to 14; an aerosol generating system comprising: an aerosol generating device having a heating chamber arranged to receive at least a distal portion of the cartridge, the heating chamber being at least partially surrounded by an inductor coil.

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