Cartridge with element for forming a liquid meniscus for an aerosol generating system - Patent Application 20070122967

Abstract

A cartridge (10) for an aerosol generation system, the cartridge (10) comprising: an air inlet (32) and an air outlet (38); an airflow passage (26, 48) extending between the air inlet (32) and the air outlet (38); a liquid reservoir (44) containing a liquid aerosol-forming substrate (42); a heater assembly (12) comprising at least one heating element (16, 18) in fluid communication with the airflow passage (26, 48); and the heater assembly (12) configured to heat the liquid aerosol-forming substrate (42) supplied from the liquid reservoir (44) to a surface of the heater assembly (12) to generate an aerosol. The cartridge further comprises at least one meniscus-forming element (101, 102), the at least one meniscus-forming element (101, 102) being adjacent to the heater assembly (12). Each meniscus forming element (101, 102) is positioned within the airflow passage (26, 48) and is either in contact with the surface of the heater assembly (12) or spaced apart from the surface of the heater assembly (12) such that, during use, a meniscus of the liquid aerosol-forming substrate (42) is formed between the surface of the heater assembly (12) and at least one meniscus forming element (101, 102).

Description

[Technical Field]

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

[0002] Aerosol-generating systems and devices configured to generate inhalable aerosols from an aerosol-forming substrate are known in the art. Some prior aerosol-generating systems include an aerosol-generating device connectable 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.

[0003] The aerosol-forming substrate may be a liquid. In this case, the cartridge or device 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 inductively heated. An airflow is provided past the heating element to entrain the generated vapor. The vapor condenses in the airflow, and an aerosol is formed. The aerosol may then be inhaled by the user. The aerosol generating device typically includes a power source configured to provide power to the heating element. In an aerosol generating system including a device and a cartridge, the power source is often configured to provide power to the heating element when the device and cartridge are coupled together via an electrical connector.

[0004] In this type of aerosol generating system, the system is often configured to activate the heating element only when the user is taking a puff on the system.

[0005] Towards the end of a user's puff, the liquid aerosol-forming substrate present on the heating element may be completely vaporized, and the transport of the liquid aerosol-forming substrate to the heating element by the wicking material is often limited by the diffusion rate of the liquid aerosol-forming substrate through the wicking element to the heating element. This rate of diffusion of the liquid aerosol-forming substrate through the wicking element to the heating element is often not fast enough to meet the aerosol generation desired by the user. Thus, when a user takes a long or strong puff with an aerosol generating system or device, aerosol generation may be reduced towards the end of the puff. Reduction in aerosol generation and delivery may be detrimental to the user's overall experience.

[0006] It would therefore be desirable to provide cartridges for aerosol generating systems, aerosol generating systems, and aerosol generating devices that increase the amount of liquid aerosol-forming substrate available to be vaporized by a heating element. Summary of the Invention

[0007] According to a first embodiment of the present disclosure, there is provided a cartridge for an aerosol generation system. The cartridge may include an air inlet and an air outlet. The cartridge may include an airflow passage extending between the air inlet and the air outlet. The cartridge may include a liquid reservoir containing a liquid aerosol-forming substrate. The cartridge may include a heater assembly including at least one heating element in fluid communication with the airflow passage. The heater assembly may be configured to heat the liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol. The cartridge may include at least one meniscus-forming element proximate to the heater assembly. Each meniscus-forming element may be positioned within the airflow passage. Each meniscus-forming element may contact the surface of the heater assembly or may be spaced apart from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus-forming element. Advantageously, each meniscus-forming element provides an excess volume of liquid aerosol-forming substrate relative to the liquid aerosol-forming substrate already present in the heater assembly, thus providing more liquid aerosol-forming substrate available to the heater assembly to be vaporized during a puff.

[0008] Furthermore, each meniscus forming element may provide mechanical support to the heater assembly, which is particularly advantageous when each meniscus forming element contacts the heater assembly, for example, each meniscus forming element may limit deformation of the heater assembly.

[0009] Each meniscus-forming element may be in contact with the surface of the heater assembly or may be spaced 0 to 3 millimeters from the surface of the heater assembly. Preferably, each meniscus-forming element is in contact with the surface of the heater assembly or spaced 0 to 1 millimeter from the surface of the heater assembly. Advantageously, such a distance from the surface of the heater assembly ensures that a meniscus can be reliably formed by the liquid aerosol-forming substrate at room temperature.

[0010] Preferably, each meniscus-forming element does not contact the surface of the heater assembly. Preferably, each meniscus-forming element is spaced 0 to 3 millimeters from the surface of the heater assembly and does not contact the surface of the heater assembly. More preferably, each meniscus-forming element is spaced 0 to 1 millimeter from the surface of the heater assembly and does not contact the surface of the heater assembly. Advantageously, spacing each meniscus-forming element from the surface of the heater assembly avoids direct contact between the heater assembly and each meniscus-forming element, since heat from the heater assembly could damage the meniscus-forming element if the two were in contact. Furthermore, this reduces heat loss that could occur from the heater assembly to the meniscus-forming element if the two were in contact.

[0011] The at least one heating element may form at least a portion of the surface of the heater assembly. Preferably, the at least one heating element forms a majority of the surface of the heater assembly. The at least one heating element may form the entire surface of the heater assembly. The at least one heating element may form the entire surface of the heater assembly located within the airflow passage. Each meniscus-forming element may be in contact with the surface of the at least one heating element or may be spaced apart from the surface of the at least one heating element such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the at least one heating element and the at least one meniscus-forming element.

[0012] Each meniscus-forming element may be an elongated element. Each meniscus-forming element may have a tip proximate to the heater assembly, with each tip contacting the surface of the heater assembly or spaced from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus-forming element. Advantageously, having the tip of each meniscus-forming element proximate to the heater assembly ensures that a sufficient surface of the heater assembly is exposed to the airflow passage so that vapor can be drawn from the heater assembly and aerosolized within the airflow passage.

[0013] A tip may be defined as a pointed or rounded end of a meniscus forming element. A tip may also or alternatively be defined as the tip of a narrow or tapered region of a meniscus forming element.

[0014] The airflow passage may be defined by an airflow passage wall. The airflow passage wall may include an interior surface and the at least one meniscus forming element may extend from the interior surface. Advantageously, such features may increase the robustness of the cartridge and simplify manufacture of the cartridge.

[0015] The at least one heating element can include a susceptor element configured to be inductively heated. Advantageously, the inductive heating allows for wireless coupling between the susceptor element disposed within the cartridge and an aerosol-generating device configured to receive the cartridge. In this manner, the liquid aerosol-forming substrate contained within a reservoir within the cartridge can be kept completely shielded from any electrical connection throughout its shelf life and during operation when coupled to an aerosol-generating device.

[0016] The at least one heating element may be configured to be resistively heated.

[0017] The at least one heating element may include at least one fluid-permeable heating element. For example, the at least one heating element may include any one of a perforated plate, a grid, a plurality of filaments with gaps disposed therebetween, or a single filament, or a combination thereof. The single filament may, for example, be serpentine-shaped. The at least one heating element preferably includes at least one mesh heating element. The at least one heating element may include at least one planar heating element. A planar element may be defined as an element extending in two orthogonal directions that is significantly greater than a third direction orthogonal to the first two directions.

[0018] Each of the at least one heating element may comprise a high temperature zone that reaches a maximum temperature during use, and the at least one meniscus-forming element may be proximate to the high temperature zone. Advantageously, a meniscus formed by each meniscus-forming element in the high temperature zone may locally reduce the temperature in the high temperature zone due to an increase in the volume of liquid present for aerosolization. This may ensure that the heating element does not overheat or dry out in the high temperature zone, which may result in the production of undesirable compounds due to excessive heat.

[0019] The airflow passage may extend longitudinally such that the direction of airflow through the airflow passage past the heater assembly is longitudinal. The heater assembly may extend transversely to the airflow passage. Advantageously, this may provide a large surface area for heating and vaporizing the liquid aerosol-forming substrate. The heater assembly may further comprise a wicking element in fluid communication with at least one heating element and a liquid reservoir. The wicking element may advantageously ensure reliable delivery of the liquid aerosol-forming substrate from the reservoir to the heating element.

[0020] The wicking element may be planar. The wicking element may be in the form of a sheet. The heater assembly may be planar. The heating assembly may be in the form of a sheet. The heating assembly may at least partially surround the wicking element. The wicking direction of the liquid aerosol-forming substrate within the wicking element may be parallel to a surface of the at least one heating element. The at least one heating element may comprise a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element facing the second side of the wicking element. The first side may be substantially parallel to the second side. The first heating element portion may be substantially parallel to the second heating element portion.

[0021] The first heating element portion and the second heating element portion may be integral with one another. The heating element may be wrapped around the wicking element such that the heating element contacts a first side of the wicking element and a second side of the wicking element opposite the first side of the wicking element. The heating element may include one or more strip bands of heating material wrapped around a portion of the wicking element such that the band substantially surrounds the wrapped portion. Advantageously, this may simplify manufacturing of the heater assembly. The first heating element portion and the second heating element portion may be separate heating elements. Both the first heating element portion and the second heating element portion may be planar.

[0022] The meniscus of the liquid aerosol-forming substrate may be formed between the surface of the heater assembly and the at least one meniscus-forming element at room temperature.The meniscus of the liquid aerosol-forming substrate may be formed between the surface of the heater assembly and the at least one meniscus-forming element at standard temperature and pressure.

[0023] A meniscus of the liquid aerosol-forming substrate can be formed between the surface of the heater assembly and the at least one meniscus-forming element when the liquid aerosol-forming substrate wets the at least one meniscus-forming element with sufficient adhesive force to balance the formation of a meniscus depending on the orientation of the cartridge and the force of gravity acting against the change in surface energy that occurs when the meniscus is formed.

[0024] The at least one meniscus-forming element may include a first meniscus-forming element and a second meniscus-forming element. The first meniscus-forming element may be in contact with the first heating element portion or may be spaced apart from the first heating element portion so that, during use, a first meniscus of the liquid aerosol-forming substrate is formed between the surface of the first heating element portion and the first meniscus-forming element. The second meniscus-forming element may be in contact with the second heating element portion or may be spaced apart from the second heating element portion so that, during use, a second meniscus of the liquid aerosol-forming substrate is formed between the surface of the second heating element portion and the second meniscus-forming element.

[0025] The first meniscus forming element and the second meniscus forming element may be positioned on directly opposite sides of the heater assembly. Advantageously, having two meniscus forming elements positioned on opposite sides of the heater assembly can provide enhanced mechanical support to the heater assembly. This is particularly advantageous when both meniscus forming elements contact the heater assembly such that they limit deformation of the heater assembly in any direction perpendicular to the plane of the heater assembly.

[0026] The wicking element may be positioned on a first surface of at least one heating element. The wicking element may be positioned on a first surface of a first heating element portion. The wicking element may be positioned on a first surface of a second heating element portion.

[0027] At least one meniscus forming element may be proximate to a second surface of the at least one heating element opposite the first surface. The first meniscus forming element may be proximate to a second surface of the first heating element portion opposite the first surface of the first heating element portion. The second meniscus forming element may be proximate to a second surface of the second heating element portion opposite the first surface of the second heating element portion.

[0028] Each meniscus forming element may contact the second surface of the at least one heating element or may be spaced 0 to 3 millimeters from the second surface of the at least one heating element, and preferably each meniscus forming element contacts the second surface of the at least one heating element or is spaced 0 to 1 millimeter from the second surface of the at least one heating element.

[0029] Preferably, each meniscus forming element does not contact the second surface of the at least one heating element. Preferably, each meniscus forming element is spaced 0 to 3 mm from the second surface of the at least one heating element and does not contact the second surface of the at least one heating element. More preferably, each meniscus forming element is spaced 0 to 1 mm from the second surface of the at least one heating element and does not contact the second surface of the at least one heating element.

[0030] The first meniscus forming element and the second meniscus forming element may be adjacent to a central portion of the heater assembly. The first meniscus forming element may extend perpendicular to a surface of the first heating element portion. The second meniscus forming element may extend perpendicular to a surface of the second heating element portion. At least one meniscus forming element may comprise at least one blade. Advantageously, each meniscus forming element may be simple to manufacture as a blade, particularly compared to a needle, as disclosed below. The at least one blade may comprise a tip. The at least one blade may extend perpendicular to a surface of the heater assembly. The at least one blade may extend in a longitudinal direction of the airflow passage. The tip of the at least one blade may extend in a longitudinal direction of the airflow passage. Advantageously, the at least one blade extending in a longitudinal direction of the airflow passage may minimize the effect on the withdrawal resistance of the cartridge when connected to an aerosol generation device. At least one blade may extend longitudinally through the airflow passage over 10% to 100% of the length of the heater assembly. Preferably, at least one blade extends longitudinally through the airflow passage over 20% to 80% of the length of the heater assembly. More preferably, at least one blade extends longitudinally through the airflow passage over 30% to 70% of the length of the heater assembly. Even more preferably, at least one blade extends longitudinally through the airflow passage over 40% to 60% of the length of the heater assembly. Even more preferably, at least one blade extends longitudinally through the airflow passage over approximately 50% of the length of the heater assembly.

[0031] The at least one meniscus-forming element may include at least one peripheral meniscus-forming element. Each of the at least one peripheral meniscus-forming element may be adjacent to a peripheral portion of the heater assembly. The heater assembly may include multiple peripheral portions, each of the peripheral portions of the heater assembly being located adjacent to an airflow passage wall. Advantageously, each peripheral meniscus-forming element may further provide an extra volume of liquid aerosol-forming substrate to the liquid aerosol-forming substrate already present in the wicking material in a region of the heater assembly that may be furthest from the first and second meniscus-forming elements. Thus, each peripheral meniscus-forming element may further provide more liquid aerosol-forming substrate available to the heater assembly to be vaporized during a puff in regions of the heater assembly that are not yet adjacent to the meniscus-forming element.

[0032] The at least one peripheral meniscus-forming element may include a first set of peripheral meniscus-forming elements and a second set of peripheral meniscus-forming elements. The first set of peripheral meniscus-forming elements may be in contact with the first heating element portion or may be spaced apart from the first heating element portion so that, during use, a meniscus of the first set of liquid aerosol-forming substrates is formed between the surface of the first heating element portion and the peripheral meniscus-forming elements of the first set. The second set of peripheral meniscus-forming elements may be in contact with the second heating element portion or may be spaced apart from the second heating element portion so that, during use, a meniscus of the second set of liquid aerosol-forming substrates is formed between the surface of the second heating element portion and the peripheral meniscus-forming elements of the second set. The at least one peripheral meniscus-forming element may include at least one peripheral meniscus-forming blade. The at least one peripheral meniscus-forming blade may extend 10% to 100% of the length of the heater assembly in the longitudinal direction of the airflow passage. Preferably, the at least one peripheral meniscus forming blade extends 20% to 80% of the length of the heater assembly in the longitudinal direction of the airflow passage. More preferably, the at least one peripheral meniscus forming blade extends 30% to 70% of the length of the heater assembly in the longitudinal direction of the airflow passage. Even more preferably, the at least one peripheral meniscus forming blade extends 40% to 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Even more preferably, the at least one peripheral meniscus forming blade extends approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0033] The at least one meniscus forming element may include at least one needle. The at least one needle may extend perpendicular to the longitudinal axis of the airflow passage. Advantageously, each meniscus forming element that is a needle may have a minimal effect on the withdrawal resistance for the cartridge when coupled to the aerosol generation device, compared to other forms of each meniscus forming element.

[0034] The at least one meniscus forming element may be integral with the airflow passage wall. The at least one meniscus forming element and the airflow passage wall may be formed by injection molding. Advantageously, both of these two features may increase the robustness of the cartridge and simplify its manufacture. The at least one meniscus forming element and the airflow passage wall may comprise polyetheretherketone (PEEK).

[0035] The cartridge may further comprise a mouthpiece. The mouthpiece may include an air outlet. The liquid reservoir may at least partially surround the airflow passage. The liquid reservoir may surround the airflow passage.

[0036] According to a second embodiment of the present disclosure, there is provided an aerosol generation system comprising a cartridge and an aerosol generating device. The cartridge may comprise an air inlet and an air outlet. The cartridge may comprise an airflow passage extending between the air inlet and the air outlet. The cartridge may comprise a liquid reservoir containing a liquid aerosol-forming substrate. The cartridge may comprise a heater assembly comprising at least one heating element in fluid communication with the airflow passage. The heater assembly may be configured to heat the liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol. The cartridge may comprise at least one meniscus-forming element, the at least one meniscus-forming element being proximate to the heater assembly. Each meniscus-forming element may be positioned within the airflow passage. Each meniscus-forming element may contact the surface of the heater assembly or may be spaced apart from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus-forming element. The aerosol generating device may comprise a power source. The power supply may be configured to supply power to the heating element. The aerosol generation device may include a control circuit. The control circuit may be configured to control the supply of power from the power supply to the at least one heating element. The cartridge may be reversibly connectable to the aerosol generation device.

[0037] The aerosol generating device may further include an inductor element. The at least one heating element may include a susceptor element configured to be inductively heated by an inductor. The inductor element may be a helical coil. Alternatively, the inductor element may be at least one planar coil. For example, the inductor element may be two planar coils. The two planar coils may be positioned on opposite sides of the susceptor element when the cartridge is connected to the aerosol generating device. The inductor element may include copper.

[0038] The inductor element may at least partially surround the susceptor element when the cartridge is coupled to the aerosol generating device.

[0039] The aerosol generating device may further comprise a magnetic flux concentrating element, which may at least partially surround the inductor element. Advantageously, the magnetic flux concentrating element may increase the efficiency of an induction device comprising the inductor element and the susceptor element.

[0040] Alternatively, the heating element may be configured to be resistively heated. The aerosol generation device may further comprise device electrical contacts. The cartridge may comprise cartridge electrical contacts in electrical contact with the at least one heating element. The device electrical contacts and cartridge electrical contacts may be in electrical contact when the cartridge is coupled to the aerosol generation device.

[0041] The aerosol generating device may comprise a cavity. The aerosol generating device may comprise a cavity into which at least a portion of the cartridge is located when the cartridge is coupled to the aerosol generating device.

[0042] The control circuit may further comprise a puff detector. The puff detector may be configured to be in fluid communication with the airflow passage when the cartridge is coupled to the aerosol generating device. The aerosol generating system may be configured such that the at least one heating element is activated by a puff. Advantageously, therefore, aerosol is only generated when a user puffs on the system.

[0043] The aerosol generation system may comprise a cartridge according to the first embodiment of the present disclosure, and therefore optional features of the cartridge according to the first embodiment of the present disclosure may equally be present in the cartridge of the aerosol generation system according to the second embodiment of the present disclosure.

[0044] According to a third embodiment of the present disclosure, there is provided an aerosol generating device. The aerosol generating device may include an air inlet and an air outlet. The aerosol generating device may include an airflow passage extending between the air inlet and the air outlet. The aerosol generating device may include a liquid reservoir containing a liquid aerosol-forming substrate. The aerosol generating device may include a heater assembly including at least one heating element in fluid communication with the airflow passage. The heater assembly may be configured to heat the liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol. The aerosol generating device may include at least one meniscus-forming element. The at least one meniscus-forming element may be adjacent to the heater assembly.

[0045] Each meniscus forming element may be located within the airflow passage and may be in contact with the surface of the heater assembly, or may be spaced apart from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and at least one meniscus forming element.

[0046] The aerosol generating device may comprise a power supply, which may be configured to provide power to the heating element.

[0047] The aerosol generating device may include a control circuit. The control circuit may be configured to control the supply of power from the power source to the at least one heating element. The aerosol generating device may be a handheld aerosol generating device. The control circuit may further include a puff detector in fluid communication with the airflow passage. The aerosol generating device may be configured such that the at least one heating element is activated by a puff. The aerosol generating device may include a mouthpiece. The mouthpiece may include an air outlet.

[0048] The aerosol generating device may include an inductor element. The at least one heating element may include a susceptor element configured to be inductively heated by an inductor. The inductor element may be a helical coil. The inductor element may include copper. The inductor element may at least partially surround the susceptor element. The aerosol generating device may further include a magnetic flux concentrating element. The magnetic flux concentrating element may at least partially surround the inductor element. Alternatively, the heating element may be in electrical contact with a power source and configured to be resistively heated.

[0049] Each meniscus-forming element may be in contact with the surface of the heater assembly or may be spaced 0 to 3 millimeters from the surface of the heater assembly. Preferably, each meniscus-forming element is in contact with the surface of the heater assembly or spaced 0 to 1 millimeter from the surface of the heater assembly. Advantageously, such a distance from the surface of the heater assembly ensures that a meniscus can be reliably formed by the liquid aerosol-forming substrate at room temperature.

[0050] Preferably, each meniscus forming element is spaced apart from the surface of the heater assembly. Preferably, each meniscus forming element does not contact the surface of the heater assembly. Preferably, each meniscus forming element is spaced apart from the surface of the heater assembly by 0 to 3 millimeters and does not contact the surface of the heater assembly. More preferably, each meniscus forming element is spaced apart from the surface of at least one heating element by 0 to 1 millimeter and does not contact the surface of the heater assembly. Advantageously, spaced apart from the surface of the heater assembly, each meniscus forming element avoids direct contact between the heater assembly and each meniscus forming element, since heat from the heater assembly could damage the meniscus forming element if the two were to come into contact.

[0051] Each meniscus-forming element may be an elongated element. Each meniscus-forming element may have a tip proximate to the heater assembly, with each tip contacting the surface of the heater assembly or spaced from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of the at least one meniscus-forming element. Advantageously, having the tip of each meniscus-forming element proximate to one of the at least one heating element ensures that a sufficient surface of the heater assembly is exposed to the airflow passage so that vapor can be drawn from the heater assembly and aerosolized within the airflow passage.

[0052] The airflow passage may be defined by an airflow passage wall. The airflow passage wall may include an inner surface and the at least one meniscus forming element may extend from the inner surface. Advantageously, such features may increase the robustness of the device and simplify manufacture of the device.

[0053] The at least one heating element may include at least one mesh heating element. The at least one heating element may include at least one planar heating element. A planar element may be defined as an element extending in two orthogonal directions that is significantly greater than a third direction orthogonal to the first two directions.

[0054] Each of the at least one heating element may comprise a high temperature zone that reaches a maximum temperature during use, and the at least one meniscus-forming element may be proximate to the high temperature zone. Advantageously, a meniscus formed by each meniscus-forming element in the high temperature zone may locally reduce the temperature in the high temperature zone due to an increase in the volume of liquid present for aerosolization. This may ensure that the heating element does not overheat or dry out in the high temperature zone, which may result in the production of undesirable compounds due to excessive heat.

[0055] The airflow passage may extend longitudinally such that the direction of airflow through the airflow passage is longitudinal. The heater assembly may extend transversely to the airflow passage. Advantageously, this may provide a larger surface area for heating and vaporizing the liquid aerosol-forming substrate. The heater assembly may further comprise a wicking element in fluid communication with the at least one heating element and the liquid reservoir. The wicking element may advantageously ensure reliable delivery of the liquid aerosol-forming substrate from the reservoir to the heating element.

[0056] The wicking element may be planar. The heater assembly may be planar. A wicking direction of the liquid aerosol-forming substrate within the wicking element may be parallel to a surface of the heater assembly. The at least one heating element may comprise a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element facing the second side of the wicking element.

[0057] The first heating element portion and the second heating element portion may be integral with one another. Advantageously, this may simplify manufacturing of the heater assembly. The first heating element portion and the second heating element portion may be separate heating elements. Both the first heating element portion and the second heating element portion may be planar.

[0058] The meniscus of the liquid aerosol-forming substrate may be formed between the surface of the heater assembly and the at least one meniscus-forming element at room temperature.The meniscus of the liquid aerosol-forming substrate may be formed between the surface of the heater assembly and the at least one meniscus-forming element at standard temperature and pressure.

[0059] The at least one meniscus-forming element may include a first meniscus-forming element and a second meniscus-forming element. The first meniscus-forming element may be in contact with the first heating element portion or may be spaced apart from the first heating element portion such that, in use, a first meniscus of the liquid aerosol-forming substrate is formed between a surface of the first heating element portion and the first meniscus-forming element, and the second meniscus-forming element may be in contact with the second heating element portion or may be spaced apart from the second heating element portion such that, in use, a second meniscus of the liquid aerosol-forming substrate is formed between a surface of the second heating element portion and the second meniscus-forming element.

[0060] The first meniscus forming element and the second meniscus forming element may be positioned on directly opposite sides of the heater assembly. Advantageously, having two meniscus forming elements positioned on opposite sides of the heater assembly can provide enhanced mechanical support to the heater assembly. This is particularly advantageous when both meniscus forming elements contact the heater assembly such that they limit deformation of the heater assembly in any direction perpendicular to the plane of the heater assembly.

[0061] The first meniscus forming element and the second meniscus forming element may be adjacent to a central portion of the heater assembly. The first meniscus forming element may extend perpendicular to the surface of the first heating element portion, and the second meniscus forming element may extend perpendicular to the surface of the second heating element portion. At least one meniscus forming element may include at least one blade. Advantageously, each meniscus forming element may be easier to manufacture as a blade, particularly compared to a needle, as disclosed below. The at least one blade may include a tip. The at least one blade may extend perpendicular to the surface of the heater assembly. The at least one blade may extend in the longitudinal direction of the airflow passage. The tip of the at least one blade may extend in the longitudinal direction of the airflow passage. Advantageously, the at least one blade extending in the longitudinal direction of the airflow passage may minimize the effect on the draw resistance of the device. The at least one blade may extend in the longitudinal direction of the airflow passage for 10% to 100% of the length of the heater assembly. Preferably, at least one blade extends longitudinally through the airflow passage for 20% to 80% of the length of the heater assembly. Even more preferably, at least one blade extends longitudinally through the airflow passage for 30% to 70% of the length of the heater assembly. Even more preferably, at least one blade extends longitudinally through the airflow passage for 40% to 60% of the length of the heater assembly. Even more preferably, at least one blade extends longitudinally through the airflow passage for approximately 50% of the length of the heater assembly.

[0062] The at least one meniscus-forming element may include at least one peripheral meniscus-forming element. Each of the at least one peripheral meniscus-forming element may be adjacent to one of a plurality of peripheral portions of the heater assembly, each peripheral portion of the heater assembly being located adjacent to an airflow passage wall. Advantageously, each peripheral meniscus-forming element may further provide an extra volume of liquid aerosol-forming substrate to the liquid aerosol-forming substrate already present in the wicking material in a region of the heater assembly that may be furthest from the first and second meniscus-forming elements. Thus, each peripheral meniscus-forming element may further provide more liquid aerosol-forming substrate available to the heater assembly to be vaporized during a puff in regions of the heater assembly that are not yet adjacent to the meniscus-forming element.

[0063] The at least one peripheral meniscus-forming element may include a first set of peripheral meniscus-forming elements and a second set of peripheral meniscus-forming elements. The first set of peripheral meniscus-forming elements may be in contact with the first heating element portion or may be spaced apart from the first heating element portion so that, during use, a meniscus of the first set of liquid aerosol-forming substrates is formed between the surface of the first heating element portion and the peripheral meniscus-forming elements of the first set. The second set of peripheral meniscus-forming elements may be in contact with the second heating element portion or may be spaced apart from the second heating element portion so that, during use, a meniscus of the second set of liquid aerosol-forming substrates is formed between the surface of the second heating element portion and the peripheral meniscus-forming elements of the second set. The at least one peripheral meniscus-forming blade may extend 10% to 100% of the length of the heater assembly in the longitudinal direction of the airflow passage. Preferably, the at least one peripheral meniscus-forming blade extends 20% to 80% of the length of the heater assembly in the longitudinal direction of the airflow passage. More preferably, the at least one peripheral meniscus forming blade extends 30% to 70% of the length of the heater assembly in the longitudinal direction of the airflow passage. Even more preferably, the at least one peripheral meniscus forming blade extends 40% to 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Even more preferably, the at least one peripheral meniscus forming blade extends approximately 50% of the length of the heater assembly in the longitudinal direction of the airflow passage.

[0064] The at least one meniscus forming element may comprise at least one needle. The at least one needle may extend perpendicular to the longitudinal axis of the airflow passage. Advantageously, each meniscus forming element that is a needle may have a minimal effect on the draw resistance for the aerosol generation device when compared to other forms of each meniscus forming element.

[0065] The at least one meniscus forming element may be integral with the airflow passage wall. The at least one meniscus forming element and the airflow passage wall may be formed by injection molding. Advantageously, both of these two features may increase the robustness of the device and simplify the manufacture of the device. The at least one meniscus forming element and the airflow passage wall may comprise polyetheretherketone (PEEK).

[0066] The liquid reservoir may at least partially surround the airflow passage. Thus, the liquid reservoir may surround the airflow passage.

[0067] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more of the features of another example, embodiment, or aspect described herein.

[0068] Example 1: 1. A cartridge for an aerosol generation system, the cartridge comprising: an air inlet and an air outlet; an airflow passage extending between the air inlet and the air outlet; a liquid reservoir containing a liquid aerosol-forming substrate; a heater assembly including at least one heating element in fluid communication with the airflow passage, the heater assembly configured to heat a liquid aerosol-forming substrate supplied from a liquid reservoir to a surface of the heater assembly to generate an aerosol; at least one meniscus forming element adjacent to the heater assembly; wherein each meniscus forming element is positioned within the airflow passage and either contacts the surface of the heater assembly or is spaced apart from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and at least one meniscus forming element. Example 2: The cartridge of example 1, wherein each meniscus forming element contacts a surface of the heater assembly or is spaced from the surface of the heater assembly by between 0 millimeters and 3 millimeters. Example 3: The cartridge of example 2, wherein each meniscus forming element contacts or is spaced from the surface of the heater assembly by between 0 millimeters and 1 millimeter. Example 4: A cartridge according to any one of Examples 1 to 3, wherein each meniscus forming element is an elongated element. Example 5: 5. The cartridge of any one of Examples 1 to 4, wherein each meniscus forming element has a tip proximate to the heater assembly, and each tip is in contact with the surface of the heater assembly or is spaced from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus forming element. Example 6: 6. The cartridge of any one of Examples 1 to 5, wherein the airflow passage is defined by an airflow passage wall, the airflow passage wall including an inner surface, and the at least one meniscus forming element extending from the inner surface. Example 7: 7. The cartridge of any of Examples 1-6, wherein the at least one heating element comprises a susceptor element configured to be inductively heated. Example 8: 7. The cartridge of any one of Examples 1 to 6, wherein at least one heating element is configured to be resistively heated. Example 9: The cartridge of any one of Examples 1 to 8, wherein the at least one heating element comprises at least one mesh heating element. Example 10: The cartridge of any one of Examples 1 to 9, wherein the at least one heating element comprises at least one planar heating element. Example 11: 11. The cartridge of any one of Examples 1 to 10, wherein each of the at least one heating element comprises a high temperature zone that reaches a maximum temperature during use, and wherein the at least one meniscus forming element is adjacent to the high temperature zone. Example 12: 12. The cartridge according to any one of Examples 1 to 11, wherein the airflow passage extends in the longitudinal direction so that the direction of the airflow passing through the airflow passage is the longitudinal direction. Example 13: 13. The cartridge of example 12, wherein the heater assembly extends across the airflow passage. Example 14: 14. The cartridge of example 12 or 13, wherein the heater assembly further comprises a wicking element in fluid communication with the at least one heating element and the liquid reservoir. Example 15: The cartridge of example 14, wherein the wicking element is planar. Example 16: The cartridge of example 15, wherein the heater assembly is planar. Example 17: The cartridge of example 16, wherein the wicking direction of the liquid aerosol-forming substrate within the wicking element is parallel to the surface of the heater assembly. Example 18: A cartridge described in any of Examples 14 to 17, wherein at least one heating element comprises a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, and the first side of the wicking element faces the second side of the wicking element. Example 19: The cartridge of example 18, wherein the first heating element portion and the second heating element portion are integral with one another. Example 20: The cartridge of example 18, wherein the first heating element portion and the second heating element portion are separate heating elements. Example 21: The cartridge according to any one of Examples 18 to 20, wherein both the first heating element portion and the second heating element portion are planar. Example 22: 22. The cartridge of any one of Examples 18 to 21, wherein the at least one meniscus forming element comprises a first meniscus forming element and a second meniscus forming element. Example 23: 23. The cartridge of example 22, wherein the first meniscus-forming element contacts the first heating element portion or is spaced apart from the first heating element portion such that, in use, a first meniscus of the liquid aerosol-forming substrate is formed between a surface of the first heating element portion and the first meniscus-forming element, and the second meniscus-forming element contacts the second heating element portion or is spaced apart from the second heating element portion such that, in use, a second meniscus of the liquid aerosol-forming substrate is formed between a surface of the second heating element portion and the second meniscus-forming element. Example 24: 24. The cartridge of example 22 or 23, wherein the first meniscus forming element and the second meniscus forming element are positioned on opposite sides of the heater assembly. Example 25: 25. The cartridge of any of Examples 22-24, wherein the first meniscus forming element and the second meniscus forming element are adjacent to a central portion of the heater assembly. Example 26: A cartridge described in any of Examples 22 to 25, wherein the first meniscus forming element extends perpendicular to the surface of the first heating element portion, and the second meniscus forming element extends perpendicular to the surface of the second heating element portion. Example 27: 27. The cartridge of any one of Examples 12 to 26, wherein the at least one meniscus forming element comprises at least one blade, and the at least one blade comprises a tip. Example 28: 28. The cartridge of example 27, wherein at least one blade extends perpendicular to a surface of the heater assembly. Example 29: 29. The cartridge of example 27 or 28, wherein at least one blade extends longitudinally of the airflow passage. Example 30: 30. The cartridge of embodiment 29, wherein the tip of at least one blade extends in the longitudinal direction of the airflow passage. Example 31: 31. The cartridge of claim 29 or 30, wherein at least one blade extends longitudinally of the airflow passage for 10% to 100% of the length of the heater assembly. Example 32: 32. The cartridge of claim 31, wherein the at least one blade extends longitudinally of the airflow passage for 20% to 80% of the length of the heater assembly. Example 33: 33. The cartridge of claim 32, wherein the at least one blade extends longitudinally of the airflow passage for 30% to 70% of the length of the heater assembly. Example 34: 34. The cartridge of claim 33, wherein the at least one blade extends longitudinally of the airflow passage for 40% to 60% of the length of the heater assembly. Example 35: 35. The cartridge of example 34, wherein the at least one blade extends longitudinally of the airflow passage for approximately 50% of the length of the heater assembly. Example 36: The cartridge of any one of Examples 12 to 35, wherein the at least one meniscus forming element comprises at least one peripheral meniscus forming element. Example 37: A cartridge as described in Example 36, wherein each of the at least one peripheral meniscus forming element is adjacent to one of a plurality of peripheral portions of the heater assembly, and each of the peripheral portions of the heater assembly is located adjacent to an airflow passage wall. Example 38: 38. The cartridge of example 36 or 37, wherein the at least one peripheral meniscus forming element comprises a first set of peripheral meniscus forming elements and a second set of peripheral meniscus forming elements. Example 39: The cartridge of Example 38 when dependent on Example 18, wherein the first set of peripheral meniscus-forming elements contact the first heating element portion or are spaced apart from the first heating element portion such that, during use, a meniscus of the first set of liquid aerosol-forming substrates is formed between a surface of the first heating element portion and the peripheral meniscus-forming elements of the first set, and the second set of peripheral meniscus-forming elements contact the second heating element portion or are spaced apart from the second heating element portion such that, during use, a meniscus of the second set of liquid aerosol-forming substrates is formed between a surface of the second heating element portion and the peripheral meniscus-forming elements of the second set. Example 40: A cartridge described in any of Examples 36 to 39, wherein at least one peripheral meniscus forming element includes at least one peripheral meniscus forming blade, and the at least one peripheral meniscus forming blade extends in the longitudinal direction of the airflow passage over 20% to 80% of the length of the heater assembly. Example 41: 41. The cartridge of claim 40, wherein the at least one peripheral meniscus-forming blade extends longitudinally of the airflow passage over 30% to 70% of the length of the heater assembly. Example 42: 42. The cartridge of claim 41, wherein the at least one peripheral meniscus-forming blade extends longitudinally of the airflow passage over 40% to 60% of the length of the heater assembly. Example 43: 43. The cartridge of example 42, wherein the at least one peripheral meniscus-forming blade extends longitudinally of the airflow passage along approximately 50% of the length of the heater assembly. Example 44: The cartridge of any one of Examples 12 to 43, wherein the at least one meniscus forming element comprises at least one needle. Example 45: 45. The cartridge of example 44, wherein at least one needle extends perpendicular to the longitudinal axis of the airflow passage. Example 46: 46. The cartridge of any one of Examples 1 to 45, wherein at least one meniscus formation element is integral with an airflow passage wall. Example 47: 47. The cartridge of example 46, wherein at least one meniscus forming element and airflow passage wall are formed by injection molding. Example 48: 48. The cartridge of any of Examples 1-47, wherein at least one meniscus forming element and the airflow passage wall comprises polyetheretherketone (PEEK). Example 49: The cartridge of any one of Examples 1 to 48, further comprising a mouthpiece having an air outlet. Example 50: 50. The cartridge of any one of Examples 1 to 49, wherein the liquid reservoir surrounds the airflow passage. Example 51: 1. An aerosol generation system comprising a cartridge, an air inlet and an air outlet; an airflow passage extending between the air inlet and the air outlet; a liquid reservoir containing a liquid aerosol-forming substrate; a heater assembly including at least one heating element in fluid communication with the airflow passage, the heater assembly configured to heat a liquid aerosol-forming substrate supplied from a liquid reservoir to a surface of the heater assembly to generate an aerosol; at least one meniscus forming element adjacent to the heater assembly; a cartridge, wherein each meniscus forming element is positioned within the airflow passage and either contacts a surface of the heater assembly or is spaced from a surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and at least one meniscus forming element; and An aerosol generating device, comprising: a power source configured to provide power to the heating element; a control circuit configured to control power supply from the power source to the at least one heating element; Here, the aerosol generating system is one in which the cartridge is reversibly connectable to the aerosol generating device. Example 52: An aerosol generation system as described in Example 51, wherein the aerosol generating device further comprises an inductor element, and wherein at least one heating element comprises a susceptor element configured to be inductively heated by the inductor. Example 53: 53. The aerosol generation system of Example 52, wherein the inductor element is a helical coil. Example 54: 54. An aerosol generation system as described in Example 52 or 53, wherein the inductor element comprises copper. Example 55: 55. The aerosol generation system of any one of Examples 52 to 54, wherein the inductor element at least partially surrounds the susceptor element when the cartridge is coupled to the aerosol generation device. Example 56: 56. An aerosol generation system as described in Example 55, wherein the aerosol generation device further comprises a magnetic flux concentrating element, the magnetic flux concentrating element at least partially surrounding the inductor element. Example 57: An aerosol generation system as described in Example 51, wherein the heating element is configured to be resistively heated, the aerosol generation device further comprises device electrical contacts, and the cartridge comprises cartridge electrical contacts that are in electrical contact with at least one heating element such that the device electrical contacts and the cartridge electrical contacts are in electrical contact when the cartridge is connected to the aerosol generation device. Example 58: 58. An aerosol generation system according to any one of Examples 51 to 57, wherein the aerosol generation device comprises a cavity in which at least a portion of the cartridge is located when the cartridge is connected to the aerosol generation device. Example 59: An aerosol generation system described in any of Examples 51 to 58, wherein the control circuit further comprises a smoke detector, the smoke detector configured to be fluidly connected to the airflow passage when the cartridge is connected to the aerosol generating device, and the aerosol generation system is configured such that at least one heating element is activated by smoke. Example 60: An aerosol generation system described in any of Examples 51 to 59, wherein each meniscus forming element contacts the surface of the heater assembly or is spaced from the surface of the heater assembly by 0 millimeters to 3 millimeters. Example 61: An aerosol generating system as described in Example 60, wherein each meniscus forming element contacts the surface of the heater assembly or is spaced from the surface of the heater assembly by 0 millimeters to 1 millimeter. Example 62: 62. An aerosol generating system according to any one of Examples 51 to 61, wherein each meniscus forming element is an elongated element. Example 63: An aerosol generating system described in any of Examples 51 to 62, wherein each meniscus forming element has a tip that is close to the heater assembly and each tip is in contact with the surface of the heater assembly or is spaced from the surface of the heater assembly so that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus forming element. Example 64: An aerosol generation system described in any of Examples 51 to 63, wherein the airflow passage is defined by an airflow passage wall, the airflow passage wall having an inner surface, and at least one meniscus forming element extending from the inner surface. Example 65: 65. The aerosol generating system of any of Examples 51-64, wherein the at least one heating element comprises at least one mesh heating element. Example 66: 66. An aerosol generating system according to any one of Examples 51 to 65, wherein the at least one heating element comprises at least one planar heating element. Example 67: An aerosol generating system described in any of Examples 51 to 66, wherein each of at least one heating element has a high temperature zone that reaches a maximum temperature during use, and at least one meniscus forming element is adjacent to the high temperature zone. Example 68: 68. The aerosol generating system of any of Examples 51 to 67, wherein the airflow passage extends in a longitudinal direction such that the direction of airflow through the airflow passage is in the longitudinal direction. Example 69: An aerosol generation system as described in Example 68, wherein the heater assembly extends across the airflow passage. Example 70: An aerosol generation system described in Example 68 or 69, wherein the heater assembly further comprises a wicking element in fluid communication with at least one heating element and the liquid reservoir. Example 71: An aerosol generation system as described in Example 70, wherein the wicking element is planar. Example 72: An aerosol generation system as described in Example 71, wherein the heater assembly is planar. Example 73: 73. The aerosol-generating system of Example 72, wherein the wicking direction of the liquid aerosol-forming substrate within the wicking element is parallel to the surface of the heater assembly. Example 74: An aerosol generating system described in any of Examples 71 to 73, wherein at least one heating element comprises a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, and the first side of the wicking element faces the second side of the wicking element. Example 75: An aerosol generating system as described in Example 74, wherein the first heating element portion and the second heating element portion are integral with each other. Example 76: An aerosol generating system as described in Example 74, wherein the first heating element portion and the second heating element portion are separate heating elements. Example 77: An aerosol generating system described in any of Examples 74 to 76, wherein both the first heating element portion and the second heating element portion are planar. Example 78: An aerosol generation system described in any of Examples 74 to 77, wherein at least one meniscus forming element includes a first meniscus forming element and a second meniscus forming element. Example 79: 79. The aerosol generating system of Example 78, wherein the first meniscus-forming element is in contact with the first heating element portion or is spaced apart from the first heating element portion such that, during use, a first meniscus of the liquid aerosol-forming substrate is formed between the surface of the first heating element portion and the first meniscus-forming element, and the second meniscus-forming element is in contact with the second heating element portion or is spaced apart from the second heating element portion such that, during use, a second meniscus of the liquid aerosol-forming substrate is formed between the surface of the second heating element portion and the second meniscus-forming element. Example 80: 80. The aerosol generation system of Example 78 or 79, wherein the first meniscus forming element and the second meniscus forming element are positioned directly opposite the heater assembly. Example 81: An aerosol generation system described in any of Examples 78 to 80, wherein the first meniscus forming element and the second meniscus forming element are adjacent to a central portion of the heater assembly. Example 82: An aerosol generating system described in any of Examples 78 to 81, wherein the first meniscus forming element extends perpendicular to the surface of the first heating element portion and the second meniscus forming element extends perpendicular to the surface of the second heating element portion. Example 83: An aerosol generation system described in any one of Examples 68 to 82, wherein at least one meniscus forming element has at least one blade, and at least one blade has a tip. Example 84: An aerosol generation system as described in Example 83, wherein at least one blade extends perpendicular to the surface of the heater assembly. Example 85: An aerosol generation system described in Example 83 or 84, wherein at least one blade extends in the longitudinal direction of the airflow passage. Example 86: An aerosol generation system as described in Example 85, wherein the tip of at least one blade extends in the longitudinal direction of the airflow passage. Example 87: An aerosol generation system as described in Example 85 or 86, wherein at least one blade extends in the longitudinal direction of the airflow passage over 10% to 100% of the length of the heater assembly. Example 88: An aerosol generation system as described in Example 87, wherein at least one blade extends 20% to 80% of the length of the heater assembly in the longitudinal direction of the airflow passage. Example 89: An aerosol generation system as described in Example 88, wherein at least one blade extends 30% to 70% of the length of the heater assembly in the longitudinal direction of the airflow passage. Example 90: An aerosol generation system as described in Example 89, wherein at least one blade extends 40% to 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Example 91: An aerosol generation system as described in Example 90, wherein at least one blade extends in the longitudinal direction of the airflow passage for approximately 50% of the length of the heater assembly. Example 92: An aerosol generation system described in any of Examples 68 to 91, wherein the at least one meniscus forming element includes at least one peripheral meniscus forming element. Example 93: An aerosol generation system as described in Example 92, wherein each of at least one peripheral meniscus forming element is adjacent to one of multiple peripheral portions of the heater assembly, and each peripheral portion of the heater assembly is located adjacent to an airflow passage wall. Example 94: An aerosol generation system as described in Example 92 or 93, wherein at least one peripheral meniscus forming element includes a first set of peripheral meniscus forming elements and a second set of peripheral meniscus forming elements. Example 95: An aerosol generating system as described in Example 94 when dependent on Example 18, wherein the first set of peripheral meniscus forming elements are in contact with the first heating element portion or are spaced apart from the first heating element portion so that, during use, a meniscus of the first set of liquid aerosol-forming substrates is formed between the surface of the first heating element portion and the peripheral meniscus forming elements of the first set, and the second set of peripheral meniscus forming elements are in contact with the second heating element portion or are spaced apart from the second heating element portion so that, during use, a meniscus of the second set of liquid aerosol-forming substrates is formed between the surface of the second heating element portion and the peripheral meniscus forming elements of the second set. Example 96: An aerosol generating system described in any of Examples 92 to 95, wherein at least one peripheral meniscus forming element includes at least one peripheral meniscus forming blade, and the at least one peripheral meniscus forming blade extends in the longitudinal direction of the airflow passage over 20% to 80% of the length of the heater assembly. Example 97: An aerosol generation system as described in Example 96, wherein at least one peripheral meniscus-forming blade extends in the longitudinal direction of the airflow passage over 30% to 70% of the length of the heater assembly. Example 98: An aerosol generation system as described in Example 97, wherein at least one peripheral meniscus-forming blade extends 40% to 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Example 99: An aerosol generation system as described in Example 98, wherein at least one peripheral meniscus-forming blade extends in the longitudinal direction of the airflow passage over approximately 50% of the length of the heater assembly. Example 100: An aerosol generation system described in any of Examples 68 to 99, wherein at least one meniscus forming element comprises at least one needle. Example 101: An aerosol generation system as described in Example 100, wherein at least one needle extends perpendicular to the longitudinal axis of the airflow passage. Example 102: 102. An aerosol generating system according to any one of Examples 51 to 101, wherein at least one meniscus forming element is integral with the airflow passage wall. Example 103: An aerosol generation system as described in Example 102, wherein at least one meniscus forming element and airflow passage wall are formed by injection molding. Example 104: An aerosol generation system described in any of Examples 51 to 103, wherein at least one meniscus forming element and airflow passage wall comprises polyetheretherketone (PEEK). Example 105: 105. The aerosol generating system of any of Examples 51 to 104, further comprising a mouthpiece comprising an air outlet. Example 106: 106. The aerosol generating system of any one of Examples 51 to 105, wherein the liquid reservoir surrounds the airflow passage. Example 107: An aerosol generating device, comprising: an air inlet and an air outlet; an airflow passage extending between the air inlet and the air outlet; a liquid reservoir containing a liquid aerosol-forming substrate; a heater assembly including at least one heating element in fluid communication with the airflow passage, the heater assembly configured to heat a liquid aerosol-forming substrate supplied from a liquid reservoir to a surface of the heater assembly to generate an aerosol; at least one meniscus forming element proximate the heater assembly, at least one meniscus forming element, each meniscus forming element positioned within the airflow passage and either contacting a surface of the heater assembly or spaced apart from the surface of the heater assembly such that, in use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus forming element; a power source configured to provide power to the heating element; and a control circuit configured to control the supply of power from the power source to at least one heating element. Example 108: The aerosol generating device of Example 107, which is a handheld aerosol generating device. Example 109: An aerosol generating device as described in Example 107 or 108, wherein the control circuit further comprises a smoke detector in fluid communication with the airflow passage, and the aerosol generating device is configured such that at least one heating element is activated by smoke. Example 110: 109. The aerosol generating device according to any one of Examples 107 to 109, further comprising a mouthpiece equipped with an air outlet. Example 111: 111. The aerosol generating apparatus of any one of Examples 107 to 110, further comprising an inductor element, wherein at least one heating element comprises a susceptor element configured to be inductively heated by the inductor. Example 112: An aerosol generating device as described in Example 111, wherein the inductor element is a helical coil. Example 113: 113. An aerosol generating device as described in embodiment 111 or 112, wherein the inductor element comprises copper. Example 114: 114. The aerosol generating apparatus of any one of Examples 111 to 113, wherein the inductor element at least partially surrounds the susceptor element. Example 115: An aerosol generating device as described in Example 114, further comprising a magnetic flux concentrating element, the magnetic flux concentrating element at least partially surrounding the inductor element. Example 116: 111. The aerosol generating apparatus of any one of Examples 107 to 110, wherein the heating element is in electrical contact with a power source and is configured to be resistively heated. Example 117: An aerosol generating device described in any of Examples 107 to 116, wherein each meniscus forming element is in contact with the surface of the heater assembly or is spaced from the surface of the heater assembly by 0 millimeters to 3 millimeters. Example 118: An aerosol generating device as described in Example 117, wherein each meniscus forming element contacts the surface of the heater assembly or is spaced from the surface of the heater assembly by 0 to 1 millimeter. Example 119: An aerosol generating device according to any one of Examples 107 to 118, wherein each meniscus forming element is an elongated element. Example 120: An aerosol generating device described in any of Examples 107 to 119, wherein each meniscus forming element has a tip that is close to the heater assembly and each tip is in contact with the surface of the heater assembly or is spaced from the surface of the heater assembly so that during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the tip of at least one meniscus forming element. Example 121: 121. An aerosol generating device according to any one of Examples 107 to 120, wherein the airflow passage is defined by an airflow passage wall, the airflow passage wall having an inner surface, and at least one meniscus forming element extending from the inner surface. Example 122: 122. The aerosol generating apparatus of any of Examples 107 to 121, wherein the at least one heating element comprises at least one mesh heating element. Example 123: 123. The aerosol generating apparatus of any one of Examples 107 to 122, wherein the at least one heating element comprises at least one planar heating element. Example 124: An aerosol generating device described in any of Examples 107 to 123, wherein each of the at least one heating element has a high temperature zone that reaches a maximum temperature during use, and at least one meniscus forming element is adjacent to the high temperature zone. Example 125: 125. The aerosol generating apparatus of any one of Examples 107 to 124, wherein the airflow passage extends in the longitudinal direction so that the direction of the airflow through the airflow passage is the longitudinal direction. Example 126: An aerosol generating device as described in Example 125, wherein the heater assembly extends across the airflow passage. Example 127: An aerosol generating device described in Example 125 or 126, wherein the heater assembly further comprises a wicking element in fluid communication with at least one heating element and the liquid reservoir. Example 128: An aerosol generating device as described in Example 127, wherein the wicking element is planar. Example 129: An aerosol generating device as described in Example 128, wherein the heater assembly is planar. Example 130: An aerosol generating device as described in Example 129, wherein the wicking direction of the liquid aerosol-forming substrate within the wicking element is parallel to the surface of the heater assembly. Example 131: An aerosol generating device described in any of Examples 128 to 130, wherein at least one heating element comprises a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, and the first side of the wicking element faces the second side of the wicking element. Example 132: An aerosol generating device as described in Example 131, wherein the first heating element portion and the second heating element portion are integral with each other. Example 133: An aerosol generating device as described in Example 132, wherein the first heating element portion and the second heating element portion are separate heating elements. Example 134: The aerosol generating device according to any one of Examples 131 to 133, wherein both the first heating element portion and the second heating element portion are planar. Example 135: An aerosol generating device according to any one of Examples 131 to 134, wherein the at least one meniscus forming element comprises a first meniscus forming element and a second meniscus forming element. Example 136: An aerosol generating device as described in Example 135, wherein the first meniscus forming element is in contact with the first heating element portion or is spaced apart from the first heating element portion such that, during use, a first meniscus of the liquid aerosol-forming substrate is formed between the surface of the first heating element portion and the first meniscus forming element, and the second meniscus forming element is in contact with the second heating element portion or is spaced apart from the second heating element portion such that, during use, a second meniscus of the liquid aerosol-forming substrate is formed between the surface of the second heating element portion and the second meniscus forming element. Example 137: An aerosol generating device as described in Example 135 or 136, wherein the first meniscus forming element and the second meniscus forming element are positioned directly opposite the heater assembly. Example 138: An aerosol generating device described in any of Examples 135 to 137, wherein the first meniscus forming element and the second meniscus forming element are adjacent to a central portion of the heater assembly. Example 139: An aerosol generating device described in any of Examples 135 to 138, wherein the first meniscus forming element extends perpendicular to the surface of the first heating element portion, and the second meniscus forming element extends perpendicular to the surface of the second heating element portion. Example 140: An aerosol generating device according to any one of Examples 125 to 139, wherein at least one meniscus forming element comprises at least one blade, and at least one blade comprises a tip. Example 141: An aerosol generating device as described in Example 140, wherein at least one blade extends perpendicular to the surface of the heater assembly. Example 142: An aerosol generating device as described in Example 140 or 141, wherein at least one blade extends in the longitudinal direction of the airflow passage. Example 143: An aerosol generating device as described in Example 142, wherein the tip of at least one blade extends in the longitudinal direction of the airflow passage. Example 144: An aerosol generating device as described in Example 142 or 143, wherein at least one blade extends in the longitudinal direction of the airflow passage over 10% to 100% of the length of the heater assembly. Example 145: An aerosol generating device as described in Example 144, wherein at least one blade extends in the longitudinal direction of the airflow passage over 20% to 80% of the length of the heater assembly. Example 146: An aerosol generating device as described in Example 145, wherein at least one blade extends in the longitudinal direction of the airflow passage over 30% to 70% of the length of the heater assembly. Example 147: An aerosol generating device as described in Example 146, wherein at least one blade extends 40% to 60% of the length of the heater assembly in the longitudinal direction of the airflow passage. Example 148: An aerosol generating device as described in Example 147, wherein at least one blade extends in the longitudinal direction of the airflow passage for approximately 50% of the length of the heater assembly. Example 149: 149. The aerosol generating device of any one of Examples 125 to 148, wherein the at least one meniscus forming element comprises at least one peripheral meniscus forming element. Example 150: An aerosol generating device as described in Example 149, wherein each of at least one peripheral meniscus forming element is adjacent to one of multiple peripheral portions of the heater assembly, and each peripheral portion of the heater assembly is located adjacent to an airflow passage wall. Example 151: An aerosol generating device as described in Example 149 or 150, wherein at least one peripheral meniscus forming element includes a first set of peripheral meniscus forming elements and a second set of peripheral meniscus forming elements. Example 152: An aerosol generating device as described in Example 151 when dependent on Example 18, wherein the first set of peripheral meniscus forming elements are in contact with the first heating element portion or are spaced apart from the first heating element portion so that, during use, a meniscus of the first set of liquid aerosol-forming substrates is formed between the surface of the first heating element portion and the peripheral meniscus forming elements of the first set, and the second set of peripheral meniscus forming elements are in contact with the second heating element portion or are spaced apart from the second heating element portion so that, during use, a meniscus of the second set of liquid aerosol-forming substrates is formed between the surface of the second heating element portion and the peripheral meniscus forming elements of the second set. Example 153: An aerosol generating device described in any of Examples 149 to 152, wherein at least one peripheral meniscus forming element includes at least one peripheral meniscus forming blade, and the at least one peripheral meniscus forming blade extends in the longitudinal direction of the airflow passage over 20% to 80% of the length of the heater assembly. Example 154: An aerosol generating device as described in Example 153, wherein at least one peripheral meniscus-forming blade extends in the longitudinal direction of the airflow passage over 30% to 70% of the length of the heater assembly. Example 155: An aerosol generating device as described in Example 154, wherein at least one peripheral meniscus-forming blade extends in the longitudinal direction of the airflow passage over 40% to 60% of the length of the heater assembly. Example 156: An aerosol generating device as described in Example 155, wherein at least one peripheral meniscus-forming blade extends in the longitudinal direction of the airflow passage over approximately 50% of the length of the heater assembly. Example 157: 157. An aerosol generating device according to any one of Examples 125 to 156, wherein at least one meniscus forming element comprises at least one needle. Example 158: An aerosol generating device as described in Example 157, wherein at least one needle extends perpendicular to the longitudinal axis of the airflow passage. Example 159: An aerosol generating device according to any one of Examples 107 to 158, wherein at least one meniscus forming element is integral with the airflow passage wall. Example 160: An aerosol generating device as described in Example 159, wherein at least one meniscus forming element and the airflow passage wall are formed by injection molding. Example 161: An aerosol generating device according to any one of Examples 107 to 160, wherein at least one meniscus forming element and airflow passage wall comprises polyetheretherketone (PEEK). Example 162: 162. The aerosol generating device of any one of Examples 170 to 161, wherein the liquid reservoir surrounds the airflow passage.

[0069] Features of one embodiment of the present invention may also be applied to other aspects of the present invention. [Brief explanation of the drawings]

[0070] The embodiments will now be further described with reference to the figures.

[0071] [Figure 1A] FIG. 1A shows a schematic cross-sectional view of a cartridge for an aerosol generation system according to a first embodiment of the present disclosure, the cartridge comprising a heater holder. [Figure 1B] FIG. 1B shows a schematic diagram of an alternative cross section of the cartridge of FIG. 1A. [Figure 2] FIG. 2 shows a further alternative cross-sectional schematic view of the cartridge of FIGS. 1A and 1B. [Figure 3A]FIG. 3A shows a schematic cross-sectional view of an aerosol generation system according to a second embodiment of the present disclosure, with the cartridge separated from the aerosol generation device. [Figure 3B] FIG. 3B shows a cross-sectional schematic view of an aerosol generation system according to a second embodiment of the present disclosure, in which the cartridge is coupled to an aerosol generation device. [Figure 4] FIG. 4 shows a schematic cross-sectional view of an aerosol generating device according to a third embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0072] 1A and 1B show schematic views of two cross sections of a cartridge 10 for an aerosol generation system, the cartridge 10 being in accordance with a first embodiment of the present disclosure. The two cross sections are taken in two planes perpendicular to each other.

[0073] The cartridge 10 includes a heater holder 14 and a heater assembly 12 attached to the heater holder 14. The heater assembly 12 is planar and thin, having a thickness dimension substantially smaller than its length and width dimensions. The heater assembly 12 is shaped in a rectangular configuration and includes three layers: a first susceptor element 16, a second susceptor element 18, and a wicking element 20 disposed between the first susceptor element 16 and the second susceptor element 18. The first susceptor element 16, the second susceptor element 18, and the wicking element 20 each form a generally rectangular shape, each susceptor element having the same length and width dimensions, with the width of the susceptor elements 16, 18 being smaller than the width of the wicking element 20. Thus, the wicking element 20 includes an outer, exposed portion that each protrudes into one of the two channels 45. The first and second susceptor elements 16, 18 are substantially identical and comprise a sintered mesh formed from stainless steel filaments, e.g., ferritic or austenitic stainless steel filaments. The wicking element 20 comprises a body of porous rayon filaments. The wicking element 20 is configured to deliver liquid from an outer exposed surface of the wicking element 20 to the first and second susceptor elements 16, 18.

[0074] Each of the first susceptor element 16 and the second susceptor element 18 is configured to be heatable by penetration by an alternating magnetic field to vaporize the aerosol-forming substrate. A wicking element 20 contacts the heater holder 14 such that the heater holder 14 supports the heater assembly 12 in place within the cartridge 10.

[0075] The heater assembly 12 is partially disposed within the interior passage 26 of the tubular heater holder 14 and extends in a plane parallel to the central longitudinal axis of the heater holder 14. The first susceptor element 16 and the second susceptor element 18 are disposed entirely within the interior passage 26 of the heater holder 14, and the wicking element extends through an opening 28 in the sidewall of the heater holder 14 and into one of two channels 45.

[0076] The cartridge 10 has a mouth end and a connecting end opposite the mouth end. An outer housing 36 defines a mouth end opening 38 at the mouth end of the cartridge 10. The connecting end is configured to connect the cartridge 10 to an aerosol generating device, as described in detail below. A heater assembly 12 and a heater holder 14 are located toward the connecting end of the cartridge 10.

[0077] The outer housing 36 is formed from a moldable plastic material, such as polypropylene, and defines an interior space within which the heater assembly 12 and heater holder 14 are contained.

[0078] The outer width of the outer housing 36 is greater at the mouth end of the cartridge 10 than at the connecting end where it is joined by the shoulder 37. This allows the connecting end of the cartridge 10 to be received in the cavity of the aerosol generation device, with the shoulder 37 locating the cartridge in the correct position on the device. This also allows the mouth end of the cartridge 10 to remain outside the aerosol generation device, allowing the mouth end to conform to the external shape of the aerosol generation device.

[0079] The cartridge 10 further comprises a liquid reservoir 44. The liquid reservoir 44 is defined within the cartridge 10 for holding the liquid aerosol-forming substrate 42.

[0080] The liquid reservoir 44 extends from the mouth end of the outer housing 36 to the connecting end of the outer housing 36 and includes an annular space defined by the outer housing 36 .

[0081] The annular space has an interior passageway 48 extending between the mouth end opening 38 and the open end of the interior passageway 26 of the heater holder 14 .

[0082] The liquid reservoir 44 further includes two channels 45 defined between the inner surface of the outer housing 36 and the outer surface of the heater holder 14. The two channels 45 extend from the annular space defined by the outer housing 36 at the mouth end of the cartridge 10 to the connecting end of the cartridge 10, whereby the wicking element extends through the opening 28 in the sidewall of the heater holder 14 and into the two channels 45. The two channels 45 extend from the annular space defined by the outer housing 36 at the mouth end of the cartridge 10 opposite the interior passage 26 of the heater holder 14.

[0083] The heater holder 14 includes a base 30 that partially closes one end of the interior passage 26. The base 30 includes a plurality of air inlets 32 that allow air to be drawn into the interior passage 26 through the partially closed end.

[0084] An air passageway is formed through the cartridge 10 by the internal passageway 26 of the heater holder 14 and the internal passageway 48 of the liquid reservoir 44. The air passageway extends from the air inlet 32 in the base 30 of the heater holder 14, through the internal passageway 26 of the heater holder 14, through the internal passageway 48 of the liquid reservoir 44 to the mouth end opening 38. The air passageway allows air to be drawn through the cartridge 10 from the connecting end to the mouth end.

[0085] The heater holder 14 further comprises a first pair of meniscus-forming elements 101 and two pairs of peripheral meniscus-forming elements 102. In this particular embodiment, all of the meniscus-forming elements are elongated blades that extend parallel to the longitudinal direction of the interior passageway 26 of the heater holder 14. The meniscus-forming elements 101, 102 are positioned adjacent to the susceptor elements 16, 18 so that, in use, a meniscus of the liquid aerosol-forming substrate is formed between the susceptor elements 16, 18 and the meniscus-forming elements 101, 102. The meniscus-forming elements 101, 102 extend in a direction parallel to the longitudinal axis of the heater holder 14 for approximately half the length of the susceptor elements 16, 18. The position of the meniscus-forming elements 101, 102 can be seen more clearly in FIG. 2.

[0086] Figure 2 shows a schematic view of a further alternative cross section of cartridge 10 of Figures 1A and 1B, with cartridge 10 viewed perpendicular to the views shown in Figures 1A and 1B, such that the cross section shown in Figure 1A is indicated by dashed line AB and the cross section shown in Figure 1B is indicated by dashed line CD.

[0087] Cartridge 10 includes a heater holder 14. Heater holder 14 includes a tubular body formed from a moldable plastic material, such as polypropylene. The tubular body of heater holder 14 includes a sidewall 27 that defines an interior passageway 26 having an open end. A pair of openings 28 extend through sidewall 27 on opposite sides of tubular heater holder 14. Openings 28 are centrally disposed along the length of heater holder 14.

[0088] An opening 28 in the sidewall of the heater holder 14 is sized to receive the heater assembly 12 by a friction fit such that the heater assembly is secured within the heater holder 14. The friction fit between the heater assembly 12 and the heater holder 14 causes the mounting area 22 to directly contact the heater holder 14 at the opening 28. The heater assembly 12 and heater holder 14 are secured together such that movement of the heater holder 14 also causes movement of the heater assembly 12.

[0089] Of course, the heater assembly 12 and heater holder 14 may be secured together by other means. For example, in some embodiments, the heater assembly 12 is secured to the heater holder 14 by adhesive at the attachment area 22 of the heater assembly 12 such that the attachment area 22 is in indirect contact with the heater holder 14.

[0090] The two channels 45 are located on opposite sides of the internal passageway 26, and in use, the two channels 45 supply a liquid aerosol-forming substrate to the heater assembly 12. The wicking element 20 extends from the internal passageway 26 through the openings 28 and into both of the channels 45. Although the channels 45 are shown empty in Figure 2, it will be understood that they are filled with a liquid aerosol-forming substrate prior to use.

[0091] The cartridge 10 is shown from the mouth end to the connecting end in Figure 2. Thus, the multiple air inlet ports 32 in the base 30 are visible in Figure 2.

[0092] A cross section of heater assembly 12 can be seen more clearly in Figure 2, where wicking element 20 is disposed between first susceptor element 16 and second susceptor element 18. However, it can be understood that first susceptor element 16 and second susceptor element 18 may instead be a single susceptor element wrapped around wicking element 20, the single susceptor element including a first portion on a first side of heater assembly 12 and a second portion on a second side of heater assembly 12.

[0093] The positions of the first pair of meniscus forming elements 101 and the two pairs of peripheral meniscus forming elements 102 are also clearly visible in Figure 2. The first pair of meniscus forming elements 101 and the two pairs of peripheral meniscus forming elements 102 are all formed from a moldable plastic material such as polypropylene. The first pair of meniscus forming elements 101 are integrally molded with the sidewall 27 that defines the interior passage 26 and extend from the sidewall 27 to the first and second surfaces of the heater assembly 12. The first pair of meniscus forming elements 101 are positioned such that the first meniscus forming element is directly opposite the second meniscus forming element, which is directly opposite the heater assembly 12.

[0094] The first pair of meniscus-forming elements 101 is also centrally positioned with respect to the susceptor elements 16, 18. Thus, the first pair of meniscus-forming elements 101 is positioned furthest from the liquid reservoir 44 such that the liquid aerosol-forming substrate 42 must travel the furthest from the liquid reservoir 44 to the portion of the susceptor elements 16, 18 adjacent to the first pair of meniscus-forming elements 101. This portion of the susceptor elements 16, 18 adjacent to the first pair of meniscus-forming elements 101 is the hottest region of the susceptor elements 16, 18 when the susceptor elements 16, 18 are heated without the liquid aerosol-forming substrate 42 within the wicking element 20.

[0095] The two pairs of peripheral meniscus forming elements 102 are also integrally molded with the sidewall 27 that defines the interior passageway 26 and extend from the sidewall 27 to the first and second surfaces of the heater assembly 12. The two pairs of peripheral meniscus forming elements 102 are also positioned on opposite sides of the heater assembly 12 such that within each pair of peripheral meniscus forming elements 102, the first peripheral meniscus forming element is directly opposite the second peripheral meniscus forming element that is directly opposite the heater assembly 12.

[0096] Each meniscus forming element 101, 102 comprises a tip where the meniscus forming element 101, 102 abuts the first or second susceptor element 16. In this embodiment the tip is to a point, but one skilled in the art will understand that the tip may be of a different shape, for example the tip may be rounded.

[0097] A pair of meniscus forming elements 101 is shown forming a first pair of meniscuses 31 on opposite sides of the heating assembly 12. Two pairs of peripheral meniscus forming elements 102 are seen, each forming one of two second pairs of meniscuses 33 on opposite sides of the heating assembly 12.

[0098] FIG. 3A shows a schematic cross-sectional view of an aerosol generation system 100 according to a second embodiment of the present disclosure, with the cartridge 10 separated from the aerosol generation device 60.

[0099] Cartridge 10 is identical to that presented in Figures 1A, 1B and 2 and their corresponding descriptions.

[0100] The aerosol generating device 60 includes a generally cylindrical device outer housing 62 having a connecting end and a distal end opposite the connecting end. A cavity 64 for receiving the connecting end of the cartridge is located at the connecting end of the device 60, and an air inlet 65 is provided through the device outer housing 62 at the base of the cavity 64 to allow ambient air to be drawn into the cavity 64.

[0101] Device 60 further comprises an induction heating arrangement disposed within device outer housing 62. The induction heating arrangement includes an inductor coil 90, control circuitry 70, and a power source 72. Power source 72 comprises a rechargeable lithium-ion battery that is rechargeable via an electrical connector (not shown) at the distal end of the device. Control circuitry 70 is connected to power source 72 and inductor coil 90 such that control circuitry 70 controls the supply of power to inductor coil 90. Control circuitry 70 is configured to supply alternating current to inductor coil 90.

[0102] A single inductor coil 90 is positioned around the susceptor assembly 12 when the cartridge 10 is received in the cavity 64. The inductor coil 90 has a size and shape that matches the size and shape of the heating area of the susceptor element. The inductor coil 90 is made of copper wire with a circular cross section and disposed on a coil former element (not shown). The inductor coil 90 is a helical coil and has a circular cross section when viewed parallel to the longitudinal axis of the aerosol generating device.

[0103] The inductor coil 90 is configured such that when an alternating current is supplied to the inductor coil, the inductor coil generates an alternating magnetic field in the region of the susceptor assembly 12 when the cartridge 10 is received in the cavity 64 .

[0104] The induction heating arrangement further includes a magnetic flux concentrator element 91. The magnetic flux concentrator element 91 has a larger radius than the inductor coil 90, and therefore partially surrounds the inductor coil 90. The magnetic flux concentrator element 91 is configured to attenuate the alternating magnetic field outside the aerosol generation system. This may reduce interference between the alternating magnetic field and other nearby electronic devices and reduce the risk of the alternating magnetic field inductively heating nearby objects outside the aerosol generation system.

[0105] FIG. 3B shows a schematic cross-sectional view of the aerosol generation system 100 of FIG. 3A, but with the cartridge 10 coupled to an aerosol generation device 60.

[0106] In operation, when a user draws on mouth-end opening 38 of cartridge 10, ambient air is drawn into the base of cavity 64 through air inlet 65, as shown by the arrows in Figure 7a, and into cartridge 10 through air inlet 32 in base 30 of cartridge 10. Ambient air flows through cartridge 10, through the air passageway and over heater assembly 12, from base 30 to mouth-end opening 38.

[0107] The control circuit 70 controls the supply of power from the power supply 72 to the inductor coils 90, 91 when the system is powered up.

[0108] The control circuit 72 includes an airflow sensor 63. The airflow sensor 63 is in fluid communication with the path of ambient air drawn through the system by the user. The control circuit 72 provides power to the inductor coil 66 when the airflow sensor 63 detects a puff by the user of the cartridge 10.

[0109] When the system is activated, an alternating current is established in the inductor coils 90, 91, which generates an alternating magnetic field in the cavity 64 that penetrates the susceptor assembly 12, heating the susceptor element. The liquid aerosol-forming substrate in the channel 45 is drawn into the heater assembly 12, through the wicking element 20, and into the susceptor element. The liquid aerosol-forming substrate 42 in the susceptor element is heated, and volatile compounds from the heated aerosol-forming substrate are released into the air passage of the cartridge 10, which cools and forms an aerosol. The aerosol is entrained in air drawn through the air passage of the cartridge 10 and drawn from the cartridge 10 at the mouth-end opening 38 for inhalation by the user.

[0110] The meniscus-forming elements 101, 102 result in a meniscus of the liquid aerosol-forming substrate being formed between each of the meniscus-forming elements and one of the susceptor elements 16, 18 when the system is not activated. Then, when the system is activated, the meniscus of the liquid aerosol-forming substrate acts as an additional reservoir of liquid aerosol-forming substrate, allowing more liquid aerosol-forming substrate to be consumed per puff.

[0111] 4 shows a schematic cross-sectional view of an aerosol generating device 300 according to a third embodiment of the present disclosure. The aerosol generating device 300 according to the third embodiment of the present disclosure comprises most of the components of the aerosol generating system 100 according to the second embodiment and operates in a similar manner. Therefore, unless otherwise stated, a description of any element of the aerosol generating device 300 according to the third embodiment is the same as the description of the corresponding element of the cartridge according to the first embodiment or the aerosol generating device according to the second embodiment.

[0112] One difference is that the aerosol generating device 300 according to the third embodiment of the present disclosure does not include a separate cartridge; instead, most of the features of the cartridge 10 according to the first or second embodiment are incorporated into the aerosol generating device 300 according to the third embodiment. Furthermore, the aerosol generating device 300 according to the third embodiment of the present disclosure is resistively heated instead of being inductively heated. However, the aerosol generating device 300 according to the third embodiment of the present disclosure may equally be configured to be inductively heated instead.

[0113] As previously described, the aerosol generating device 300 according to the third embodiment includes a generally cylindrical device outer housing 362 having an oral end and a distal end opposite the oral end. An air inlet 365 is provided in the device 300 through the device outer housing 362.

[0114] The device 300 further comprises a resistive heating arrangement disposed within the device outer housing 362. The resistive heating arrangement includes a heating assembly 312, a control circuit 370, and a power source 372. The power source 372 comprises a rechargeable nickel-cadmium battery that is rechargeable via an electrical connector (not shown) at the distal end of the device. The control circuit 370 is configured to be connected to the power source 372 and the heating assembly 312 such that the control circuit 370 controls the supply of power to the heating assembly 312. The control circuit 370 is configured to supply current to the heating assembly 312, particularly to the two heating elements 316, 318. The heating assembly 312 is held within a heater holder 314.

[0115] The heater assembly 312 and heater holder 314 are identical to the heater assembly 12 and heater holder 314 shown in FIGS. 1A-3B , except that the heater assembly 312 is resistively heated instead of inductively heated. Accordingly, the two heating elements 316, 318 are both resistive heating elements. The heating elements 316, 318 are electrically connected to a power supply 372 and control circuit 370 by electrical connectors (not shown). As previously mentioned, the heater assembly 312 is planar and thin, having a thickness dimension that is substantially smaller than its length and width dimensions. The heater assembly 312 is shaped in a rectangular configuration and includes three layers: a first resistive heating element 316, a second resistive heating element 318, and a wicking element 320 disposed between the first resistive heating element 316 and the second resistive heating element 318. The first resistive heating element 316, the second resistive heating element 318, and the wicking element 320 each form a generally rectangular shape, with each resistive heating element having the same length and width dimensions, with the width of the resistive heating elements 316, 318 being less than the width of the wicking element 320. Thus, the wicking element 320 includes an outer, exposed portion of the wicking element, each protruding into one of the two channels 345. The first resistive heating element 316 and the second resistive heating element 318 are substantially identical and include a sintered mesh of steel filaments.

[0116] As previously mentioned, heater holder 314 also includes a base 330 that partially closes one end of interior passageway 326. Base 330 includes a plurality of air inlets that allow air to be drawn into interior passageway 326 through the partially closed end. As previously mentioned, heater holder 314 includes a tubular body formed from a moldable plastic material, such as polypropylene. The tubular body of heater holder 314 includes a sidewall that defines interior passageway 326 with an open end. However, those skilled in the art will understand that because device 300 does not include a removable cartridge, heater holder 314 may instead be integrally formed with device 300, and in particular device outer housing 362.

[0117] Furthermore, the arrangement and operation of the first pair of meniscus-forming elements 301 and the two pairs of peripheral meniscus-forming elements 302 are identical to those of the first and second embodiments of the present disclosure. As previously mentioned, all meniscus-forming elements 301, 302 are elongated blades that extend parallel to the longitudinal direction of the internal passage 326 of the heater holder 314. The meniscus-forming elements 301, 302 are positioned adjacent to the resistive heating elements 316, 318 so that, in use, a meniscus of the liquid aerosol-forming substrate is formed between the resistive heating elements 316, 318 and the meniscus-forming elements 301, 302. The meniscus-forming elements 301, 302 extend in a direction parallel to the longitudinal axis of the heater holder 314 for approximately half the length of the resistive heating elements 316, 318. For a complete description of the arrangement of the meniscus-forming elements 301, 302, reference should again be made to FIG. 2 and the associated description.

[0118] Similarly, with respect to the first and second embodiments of the present disclosure, the aerosol-generating device 300 further includes a liquid reservoir 344. The liquid reservoir 344 is defined by a device outer housing 362 for holding a liquid aerosol-forming substrate 342. The liquid reservoir 344 extends from the mouth end of the outer housing 362 to the connecting end of the device outer housing 362 and includes an annular space defined by the device outer housing 362. The annular space has an internal passage 348 extending between the mouth end opening 338 and the open end of the internal passage 326 of the heater holder 314. The liquid reservoir 344 further includes two channels 345, which are defined between the outer surface of the heater holder 314 and the inner surface of the device. Two channels 345 extend from the annular space defined by the device outer housing 362 at the mouth end of the device 300 to the connecting end of the device 300, whereby the wicking element 320 extends through openings in the sidewall of the heater holder 314 and into the two channels 345. The two channels 345 extend from the annular space defined by the device outer housing 362 at the mouth end of the device 300 opposite the interior passageway 326 of the heater holder 314.

[0119] Similarly, for the first and second embodiments of the present disclosure, an air passageway is formed through device 300 by interior passageway 326 of heater holder 314 and interior passageway 348 of liquid reservoir 344. The air passageway extends from the air inlet in base 330 of heater holder 314, through interior passageway 326 of heater holder 314, through interior passageway 348 of liquid reservoir 344 to mouth end opening 338. The air passageway allows air to be drawn through device 300 from air inlet 365 to mouth end opening 338.

[0120] Similarly, for the first and second embodiments of the present disclosure, control circuit 372 includes airflow sensor 363. Airflow sensor 363 is in fluid communication with the path of ambient air drawn through device 300 by a user. Control circuit 372 provides power to heating elements 316, 318 when airflow sensor 363 detects a puff by a user of device 300.

[0121] When the device is activated, an electric current is established in the resistive heating elements 316, 318, which resistively heats them. The liquid aerosol-forming substrate 342 in the channel 345 is drawn into the heater assembly 312, through the wicking element 320, and to the resistive heating elements 316, 318. The heating element heats the liquid aerosol-forming substrate 342, and volatile compounds from the heated aerosol-forming substrate are released into the air passages 326, 348 of the device 300, which cool and form an aerosol. The aerosol is entrained in air drawn through the air passages 326, 348 of the device 300 and is withdrawn from the device 300 at the mouth-end opening 338 for inhalation by the user.

[0122] Similarly, for the first and second embodiments of the present disclosure, the meniscus-forming elements 301, 302 result in a meniscus of the liquid aerosol-forming substrate being formed between each of the meniscus-forming elements and one of the resistive heating elements 316, 318 when the system is not activated. Then, when the system is activated, the meniscus of the liquid aerosol-forming substrate acts as an additional reservoir of liquid aerosol-forming substrate, allowing more liquid aerosol-forming substrate to be consumed per puff.

[0123] 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. Thus, in this context, the number A is understood as A ± 10%. Within this context, the number A may be considered to include values that are 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 cartridge for an aerosol generation system, said cartridge comprising: an air inlet and an air outlet; an air flow passage extending between the air inlet and the air outlet; a liquid reservoir containing a liquid aerosol-forming substrate; a heater assembly including at least one heating element in fluid communication with the airflow passage, the heater assembly configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; at least one meniscus forming element adjacent to the heater assembly; each meniscus forming element is positioned within the airflow passage and either contacts a surface of the heater assembly or is spaced from a surface of the heater assembly such that, in use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus forming element; A cartridge wherein the at least one meniscus forming element comprises at least one blade or at least one needle.

2. The cartridge of claim 1 , wherein each meniscus forming element contacts the surface of the heater assembly or is spaced from the surface of the heater assembly by between 0 millimeters and 3 millimeters.

3. The cartridge of claim 2 , wherein each meniscus forming element contacts the surface of the heater assembly or is spaced from the surface of the heater assembly by between 0 millimeters and 1 millimeter.

4. A cartridge according to any preceding claim, wherein the airflow passage is defined by an airflow passage wall, the airflow passage wall including an inner surface, and the at least one meniscus forming element extending from the inner surface.

5. The cartridge of any preceding claim, wherein the at least one heating element comprises a susceptor element configured to be inductively heated.

6. A cartridge according to any preceding claim, wherein each of the at least one heating element comprises a high temperature zone which reaches a maximum temperature during use, and the at least one meniscus forming element is adjacent to the high temperature zone.

7. 7. The cartridge of claim 1, wherein the heater assembly further comprises a wicking element in fluid communication with the at least one heating element and the liquid reservoir, wherein the at least one heating element comprises a first heating element portion on a first side of the wicking element and a second heating element portion on a second side of the wicking element, the first side of the wicking element facing the second side of the wicking element.

8. 8. The cartridge of claim 7, wherein the at least one meniscus forming element comprises a first meniscus forming element and a second meniscus forming element, wherein the first meniscus forming element is in contact with the first heating element part or is spaced apart from the first heating element part such that, in use, a first meniscus of the liquid aerosol-forming substrate is formed between a surface of the first heating element part and the first meniscus forming element, and the second meniscus forming element is in contact with the second heating element part or is spaced apart from the second heating element part such that, in use, a second meniscus of the liquid aerosol-forming substrate is formed between a surface of the second heating element part and the second meniscus forming element.

9. The cartridge of claim 8 , wherein the first meniscus forming element and the second meniscus forming element are adjacent a central portion of the heater assembly.

10. 10. A cartridge according to claim 1, wherein the airflow passage extends in a longitudinal direction such that the direction of airflow through the airflow passage is the longitudinal direction.

11. The cartridge of claim 10 , wherein the at least one blade includes a tip.

12. The cartridge of claim 11 , wherein the at least one blade extends perpendicular to the surface of the heater assembly, and the at least one blade extends in the longitudinal direction of the airflow passage.

13. A cartridge as described in any one of claims 4 to 12, wherein the at least one meniscus forming element includes at least one peripheral meniscus forming element, wherein each of the at least one peripheral meniscus forming element is adjacent to one of a plurality of peripheral portions of the heater assembly, and each of the peripheral portions of the heater assembly is located adjacent to the airflow passage wall.

14. 1. An aerosol generation system comprising a cartridge, the cartridge comprising: an air inlet and an air outlet; an air flow passage extending between the air inlet and the air outlet; a liquid reservoir containing a liquid aerosol-forming substrate; a heater assembly including at least one heating element in fluid communication with the airflow passage, the heater assembly configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; at least one meniscus forming element adjacent to the heater assembly; each meniscus forming element is positioned within the airflow passage and contacts the surface of the heater assembly or is spaced from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus forming element; a cartridge, wherein the at least one meniscus forming element comprises at least one blade or at least one needle; and An aerosol generating device, comprising: a power source configured to provide power to the heating element; a control circuit configured to control power supply from the power source to the at least one heating element; Here, the cartridge is reversibly connectable to the aerosol generating device, which is an aerosol generating system.

15. An aerosol generating device, comprising: an air inlet and an air outlet; an air flow passage extending between the air inlet and the air outlet; a liquid reservoir containing a liquid aerosol-forming substrate; a heater assembly including at least one heating element in fluid communication with the airflow passage, the heater assembly configured to heat a liquid aerosol-forming substrate supplied from the liquid reservoir to a surface of the heater assembly to generate an aerosol; at least one meniscus forming element adjacent to the heater assembly, each meniscus forming element is positioned within the airflow passage and contacts the surface of the heater assembly or is spaced from the surface of the heater assembly such that, during use, a meniscus of the liquid aerosol-forming substrate is formed between the surface of the heater assembly and the at least one meniscus forming element; at least one meniscus forming element, wherein the at least one meniscus forming element comprises at least one blade or at least one needle; a power source configured to provide power to the heating element; and a control circuit configured to control the supply of power from the power source to the at least one heating element.

Images