HEATER ASSEMBLY HAVING VARIABLE CROSS-SECTION HEATING ELEMENT FOR AEROSOL GENERATING DEVICES - Patent application

Abstract

A heater assembly (100) for an aerosol generating device includes a heating element (130), a first electrical contact (191) in electrical contact with a first end of the heating element (130), and a second electrical contact (192) in electrical contact with a second end of the heating element (130), wherein the heating element (130) provides a continuous electrical path between the first electrical contact (191) and the second electrical contact (192). The heating element (130) includes a plurality of heating portions (131) and at least one mounting portion (132) positioned between the heating portions (131) along the continuous electrical path. The heating element (130) further includes a frame (120) having an opening (121) in a first plane. The heating element (130) is fixed to the frame (121). Each heating portion (131) is within or over an opening (121) and is separated from the frame (120) by at least one mounting portion (132). The cross-sectional area of each heating portion (131) perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of each mounting portion (132) perpendicular to the direction of the continuous electrical path.

Description

[Technical Field]

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

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

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

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

[0005] According to one embodiment of the present disclosure, a heater assembly for an aerosol generating device is provided. The heater assembly may include a heating element, a first electrical contact in electrical contact with a first end of the heating element, and a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include a plurality of heating portions. The heating element may further include at least one mounting portion. The at least one mounting portion may be positioned between the heating portions along the continuous electrical path. The heating element may include a frame including openings in a first plane, the heating element is fixed to the frame, and each heating portion may be within or above the opening. Each heating portion may be separated from the frame by at least one mounting portion. The cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path. Advantageously, heat transfer from the heating element to the frame is reduced, thereby reducing the temperature of the frame during use.

[0006] The plurality of heating portions and the at least one mounting portion may all be integrally formed, which may advantageously simplify manufacturing and increase the robustness of the heating element.

[0007] Each mounting portion may be directly connected to exactly two heating portions. Each heating portion may be directly connected to exactly two mounting portions, or to exactly one mounting portion and either the first electrical contact or the second electrical contact. Such an arrangement may advantageously provide an electrical path that is easy to manufacture, since it ensures that the cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path can be smaller than the cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path.

[0008] Each heating portion may have a first width in a first direction and each attachment portion may have a second width in the first direction, the second width being greater than the first width. Advantageously, this provides an arrangement that ensures that the cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path can be smaller than the cross-sectional area of each attachment portion perpendicular to the direction of the continuous electrical path, and is simple to manufacture by common manufacturing methods such as laser cutting, water jet cutting, or chemical etching stamping.

[0009] Each heating portion may extend perpendicular to a first direction. The first direction may lie in a first plane. The first direction may be perpendicular to the direction of the continuous electrical path when the direction of the continuous electrical path is defined by each heating portion. The ratio of the first width to the second width may be 1 / 20 to 1 / 2. Preferably, the ratio of the first width to the second width is 1 / 10 to 1 / 4. The first width may be 0.1 mm to 2 mm. Preferably, the first width is 0.2 mm to 1 mm. More preferably, the first width is 0.2 mm to 0.5 mm.

[0010] The heating element may have a thickness in at least one direction perpendicular to the first direction. The thickness may be between 0.02 millimeters and 0.5 millimeters. Preferably, the thickness is between 0.05 millimeters and 0.3 millimeters. These dimensions may advantageously provide a heating element that is robust and capable of providing sufficient energy to heat the aerosol-forming substrate when the aerosol-generating device is a handheld device.

[0011] The heater assembly may include a gap between adjacent heating portions. The gap may have a gap width. The gap width may be in a first direction. The gap width may be between 0.1 millimeters and 1 millimeter. Preferably, the gap width is between 0.2 millimeters and 0.5 millimeters.

[0012] The plurality of heating portions may comprise between 2 and 20 heating portions. Preferably, the plurality of heating portions comprises between 3 and 9 heating portions. Still more preferably, the plurality of heating portions comprises 6 heating portions. Preferably, the plurality of heating portions comprises an even number of heating portions. Advantageously, an even number of heating portions means that the first and second electrical contacts can be positioned on the same side of the heater assembly.

[0013] The electrical resistance per unit length in the direction of the conductive path of the plurality of heating portions may be greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting portion. The electrical resistance per unit length may be measured by measuring the electrical resistance across each of the heating portions or mounting portions and dividing the electrical resistance by the length of each of the heating portions or mounting portions in the direction of the conductive path. The direction of the conductive path may be curved, for example, if the mounting portions are curved. The electrical resistance of each heating portion may be higher than the electrical resistance of each mounting portion.

[0014] The heater assembly may be configured such that when a non-zero voltage is applied across the heating element between the first and second electrical contacts, the temperature of the plurality of heating portions is greater than the temperature of the at least one mounting portion. The heater assembly may be configured such that when a non-zero current is applied through the heating element between the first and second electrical contacts, the temperature of the plurality of heating portions is greater than the temperature of the at least one mounting portion. In these cases, the temperatures of the plurality of heating portions and the at least one mounting portion may be average temperatures over the length of each of the plurality of heating portions of the at least one mounting portion.

[0015] The heating element may be serpentine-shaped. The heating element may be serpentine-shaped in the first plane. The heating element may be serpentine-shaped when projected onto the first plane. Advantageously, such an arrangement allows many heating portions to be positioned or packaged within a reduced area. Furthermore, the serpentine arrangement may be fluid-permeable. The heater assembly may include spaces between heating portions of the heating element. Thus, steam generated by the heating element may pass through the serpentine heating element.

[0016] The heating element may include stainless steel. The heating element may include a ferrimagnetic or ferromagnetic material. Advantageously, the skin depth of the ferrimagnetic or ferromagnetic material decreases when the frequency of the alternating current applied to the heating element increases. The electrical resistance of the heating element increases as a function of frequency. Therefore, the use of ferrimagnetic or ferromagnetic tracks can allow for an increase in its electrical resistance. This allows for more heat to be generated locally without reducing the thickness of the heating element or compromising its mechanical strength.

[0017] The heating element may be coated with a corrosion-resistant material. In particular, the heating element may be coated with a ceramic material. Advantageously, this may extend the life of the heating element and the heater assembly. This is particularly relevant because the heater assembly may be configured to be reversibly coupled to and separated from the wicking element, such that the heater assembly is reusable.

[0018] The heating element may be substantially flat, which may advantageously simplify the manufacture of the heating element.

[0019] The total resistance of the heating element may be between 0.1 ohms and 5 ohms, preferably between 0.2 ohms and 1.5 ohms.

[0020] The heating element and the first and second electrical contacts may be integrally formed. The heating element and the first and second electrical contacts may be formed from the same material. Advantageously, these features may simplify manufacturing of the heating element.

[0021] The opening may be substantially square or rectangular. Alternatively, the opening may be substantially circular. Advantageously, such a shape of the opening may ensure that the wicking element is easily aligned with the opening when the aerosol generating device is coupled to the cartridge. Furthermore, such a shape may make it easy to manufacture the opening or the corresponding wicking element.

[0022] The frame may be electrically insulating. In particular, the frame may have a thermal conductivity of 1 W / mK or less. This may advantageously ensure that the electrical path through the heating element is well defined as a single electrical path, minimizing current flow through the frame and therefore resistive heating of the frame.

[0023] The frame may comprise a high temperature polymer. For example, the frame may comprise polyetheretherketone (PEEK). Alternatively, the frame may comprise a ceramic. For example, the frame may comprise alumina. In another embodiment, the frame may comprise zirconia.

[0024] The frame may be overmolded over a section of the heating element. For example, the frame may be overmolded over a mounting section of the at least one mounting portion. Additionally or alternatively, the frame may be overmolded over at least a mounting section of the first electrical contact and at least a section of the second electrical contact. Advantageously, overmolding may provide a robust connection between the frame and the heating element.

[0025] The frame may include an upper element and a lower element. The upper element and the lower element may include press-fit elements such that the upper element and the lower element can be coupled together by a press fit. Alternatively, the upper element and the lower element may include snap-fit elements such that the upper element and the lower element can be coupled together by a snap fit. Alternatively, the upper element and the lower element may include fastening elements such that the upper element and the lower element can be coupled together by fastening. Advantageously, a frame including an upper element and a lower element may provide simplified manufacturing and a modular system in which, for example, the heating element can be replaced. At least a mounting section of the at least one mounting portion may be located between the upper element and the lower element when the upper element and the lower element are coupled together. Additionally or alternatively, at least a mounting section of the first electrical contact and at least a section of the second electrical contact may be located between the upper element and the lower element when the upper element and the lower element are coupled together. Advantageously, such an arrangement ensures that the heating portion does not come into contact with the frame.

[0026] The opening may have a cross-sectional area in the first plane of 1 to 1000 square millimeters. The opening preferably has a cross-sectional area in the first plane of 2 to 200 square millimeters. More preferably, the opening has a cross-sectional area in the first plane of 4 to 50 square millimeters.

[0027] The heating element may further comprise at least one thermally insulating portion. Each mounting portion may be separated from the frame by one thermally insulating portion. Advantageously, the thermal insulating portion may further reduce the amount of heat transferred from the plurality of heating portions to the frame via the at least one mounting portion.

[0028] Each heating section may be connected to the frame via at least one thermal insulating section.

[0029] The plurality of heating portions, at least one mounting portion, and at least one thermal insulating portion may all be integrally formed. Advantageously, this simplifies manufacturing as the heating element can be produced by common manufacturing methods such as laser cutting, water jet cutting, or chemical etching stamping.

[0030] Each thermal insulating section does not have to be directly attached to a heating section. There may be an attachment section intermediate each thermal insulating section and any heating section. Each thermal insulating section may be located outside of a continuous electrical path. For example, each thermal insulating section may be located outside of a continuous electrical path, and the thermal insulating section experiences a lower temperature rise due to direct resistive heating than both the temperature rise of each attachment section and the temperature rise of each heating section.

[0031] Each thermally insulating portion may have a third width in the first direction. The third width may be smaller than the second width. The ratio of the third width to the second width may be 1 / 10 to 2 / 3. The ratio of the third width to the second width is preferably 1 / 5 to 1 / 3. The third width may be approximately equal to the first width. Advantageously, this simplifies manufacturing while providing a thermally insulating portion that reduces the amount of heat transferred from the heating portion to the frame.

[0032] The thermal resistance across each attachment portion between adjacent heating portions and adjacent thermal insulating portions may be lower than the thermal resistance across each thermal insulating portion between adjacent mounting portions and the frame. Thermal resistance may be defined as the temperature difference at which an object or material resists heat flow. The thermal resistance (R) across the attachment portion between adjacent heating portions and adjacent thermal insulating portions may be defined as:

number

[0033] where x is the length of each attachment portion measured between the adjacent heating portion and the adjacent thermally insulating portion in the direction of the thermal path, A is the cross-sectional area of each attachment portion in the direction of the thermal path between the adjacent heating portion and the adjacent thermally insulating portion, and k is the thermal conductivity of each attachment portion, which is a material constant.

[0034] The thermal resistance for each thermal insulation portion between adjacent mounting portions and the frame may be defined using the same equation, where x is the length of each thermal insulation portion measured in the direction of the thermal path between the adjacent mounting portion and the frame, A is the cross-sectional area of each thermal insulation portion in the direction of the thermal path between the adjacent mounting portion and the frame, and k is the thermal conductivity of each thermal insulation portion and is a material constant.

[0035] At least one heating portion may have a radius of curvature perpendicular to the first plane. At least one heating portion may have a finite radius of curvature perpendicular to the first plane. Each heating portion may have a radius of curvature perpendicular to the first plane. At least one heating portion may extend convexly with respect to a direction in which the wicking element may be coupled to the heater assembly. At least one heating portion may have at least two sections extending in at least two different directions that are not parallel to the first plane. At least one heating portion may extend arcuately out of the first plane. At least one heating portion may extend out of the first plane in a dome. At least one heating portion may curve from the first plane. At least one heating portion may extend arcuately out of the first plane. At least one heating portion may have a radius of curvature perpendicular to the first plane such that when the at least one heating portion is reversibly deformed by a force to become parallel to the first plane, a reaction force applied by the at least one heating portion is greater at a center of the at least one heating portion than at a periphery of the at least one heating portion. Advantageously, when the aerosol generating device is coupled to the cartridge such that the heater assembly is coupled to the wicking element, the heating element may exert a greater force at the center of the connecting surface of the wicking element than at the periphery of the connecting surface of the wicking element.

[0036] Each heating segment may have the same radius of curvature perpendicular to the first plane. Alternatively, each heating segment may have a radius of curvature perpendicular to the first plane selected from a plurality of radii of curvature. For example, each heating segment may have a different radius of curvature perpendicular to the first plane.

[0037] The heater assembly may be configured such that when the wicking element is coupled to the heater assembly, the heating element exerts a non-uniform force on the connecting surface of the wicking element, for example, the heating element may exert a greater force at the center of the connecting surface of the wicking element than at the periphery of the connecting surface of the wicking element.

[0038] The heating element may comprise an elastic material, and advantageously, when the aerosol generating device is coupled to the cartridge such that the heater assembly is coupled to the wicking element, the heating element may elastically deform instead of shattering.

[0039] The frame may have an upper surface parallel to the first plane. At least a portion of the heating element may be recessed a first distance from the upper surface of the frame. The first distance may be 0.2 mm to 5 mm. Advantageously, such an arrangement may protect at least a portion of the heating element from damage, particularly when the heating element is uncovered and on an outer surface of the aerosol generating device. A mounting section of at least one mounting portion may be recessed a first distance from the upper surface of the frame.

[0040] At least a second portion of the heating element may coincide with the plane formed by the upper surface of the frame. Advantageously, such an arrangement means that the wicking element requires minimal protrusion, and the wicking element is configured to contact the heating element when a cartridge including the wicking element is coupled to an aerosol generating device including the heater assembly. At least a second portion of the heating element may coincide with the plane formed by the upper surface of the frame. At least a second portion of the heating element may extend beyond the plane formed by the upper surface of the frame. A radius of curvature perpendicular to the first plane may be applied to the second portion of the heating element.

[0041] Alternatively, the entire heating element may be recessed a first distance from the top surface of the frame. Advantageously, as noted above, such an arrangement may protect the entire heating element from damage, particularly if the heating element is uncovered and on the exterior surface of the aerosol generating device.

[0042] The frame may have a lower surface parallel to the first plane. At least a first portion of the heating element may be recessed from the lower surface of the frame by a second distance. The second distance may be 0.2 mm to 5 mm.

[0043] The mounting section of the at least one mounting portion may be recessed a second distance from the underside of the frame. Advantageously, such an arrangement may protect at least the at least one mounting portion from damage, particularly during handling of the heater assembly and aerosol generating device assembly.

[0044] The heater assembly may further include a support structure. The frame may at least partially surround the support structure. The support structure may include a support structure opening. The support structure opening may be in a first plane. The support structure opening may be substantially circular. The support structure opening may be substantially square or rectangular. The support structure opening may be substantially oval in shape. The support structure may include a high temperature polymer. For example, the support structure may include polyetheretherketone (PEEK). Alternatively, the support structure may include a ceramic. For example, the support structure may include alumina. In another example, the support structure may include zirconia. The support structure may include the same material as the frame. Alternatively, the support structure may include a different material than the frame. The support structure opening may have a cross-sectional area in the first plane between 1 square millimeter and 1000 square millimeters. The support structure opening may have a cross-sectional area in the first plane of between 2 square millimeters and 200 square millimeters, and preferably the support structure opening has a cross-sectional area in the first plane of between 4 square millimeters and 50 square millimeters.

[0045] At least a portion of the heating element may be within the support structure opening. In particular, multiple heating elements may be within the support structure opening. At least a portion of the heating element may be above the support structure opening. In particular, multiple heating elements may be above the support structure opening. Advantageously, these features allow for easy transport of the aerosol from the heating element where it is generated to the user.

[0046] The support structure may include an upper support structure surface parallel to the first plane. At least a portion of the heating element may be flush with the upper support structure surface. The plurality of heating portions may be substantially flush with the upper support structure surface. Advantageously, such an arrangement means that a minimum protrusion is required for the wicking element, which is configured to contact the heating element when a cartridge including the wicking element is coupled to an aerosol generation device including the heater assembly.

[0047] Each mounting portion may include a first section and a second section. Each first section may be substantially flush with the upper support structure surface. Each second section may extend from the upper support structure surface toward a second plane. The second plane may be parallel to, but not flush with, the upper support structure surface. Each second section may extend perpendicular to the upper support structure surface. Advantageously, this arrangement may provide a more robust structure for the heating element.

[0048] Each second section may be positioned between the frame and the support structure. Each second section may be fixed between the frame and the support structure. Advantageously, each second section may be positioned or fixed between the frame and the support structure, resulting in a heating element that is firmly fixed in place.

[0049] Both the first electrical contact and the second electrical contact may include a first electrical contact section and a second electrical contact section. Both first electrical contact sections may be substantially flush with the upper support structure surface. Both second electrical contact sections may extend from the upper support structure surface toward the second plane. Both second electrical contact sections may extend perpendicular to the upper support structure surface. Advantageously, this arrangement may provide a more robust structure for the heating element.

[0050] Both second electrical contact sections may be positioned between the frame and the support structure. Both second electrical contact sections may be fixed between the frame and the support structure. Advantageously, having both second electrical contact sections positioned or fixed between the frame and the support structure may result in a heating element that is firmly fixed in place.

[0051] The frame may include an upper surface that is coplanar with the upper support structure surface. The frame may include a lower frame surface. The support structure may include a lower support structure surface that is coplanar with the lower surface of the frame. Each of the first electrical contact and the second electrical contact may further include a third electrical contact section. Both third electrical contact sections may be substantially coplanar with the lower surface of the frame.

[0052] The heating portions may be flush with the top surface of the frame.

[0053] According to a second embodiment of the present disclosure, there is provided an aerosol generating device. The aerosol generating device may include a heater assembly. The aerosol generating device may include a heater assembly according to the first embodiment of the present disclosure. The heater assembly may include a heating element. The heater assembly may include a first electrical contact in electrical contact with a first end of the heating element. The heater assembly may include a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include a plurality of heating portions. The heating element may include at least one mounting portion positioned between the heating portions along the continuous electrical path. The heater assembly may include a frame. The frame may include openings in the first plane. The heating element may be fixed to the frame. Each heating portion may be within the opening. Each heating portion may be above the opening. Each heating portion may be separated from the frame by at least one mounting portion. The cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path.

[0054] The aerosol generating device may further include an airflow passage defined between the air inlet and the air outlet. The airflow passage may be in fluid communication with the heating element. In particular, the airflow passage may be in fluid communication with a first side of the heating element. The airflow passage may pass through the heater assembly. The heater assembly may include a heater assembly airflow passage between the heater assembly air inlet and the heater assembly air outlet. The aerosol generating device may further include a power source. The power source may be in electrical contact with the first electrical contact and the second electrical contact. The power source may be configured to supply power to the heating element. The aerosol generating device may further include control circuitry. The control circuitry may be configured to control the supply of power from the power source to the heating element.

[0055] The battery may be a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery. The battery may be a nickel metal hydride battery or a nickel cadmium battery. The power source may be another form of charge storage device, such as a capacitor.

[0056] The control circuit may be connected to the power source. The control circuit may be connected to the heating element. The control circuit may control the supply of power from the power source to the heating element. The control circuit may control the temperature of the heating element. The control circuit may comprise a controller. The control circuit may comprise a microcontroller. The microcontroller may be a programmable microcontroller.

[0057] The aerosol generating device may be a handheld aerosol generating device. The aerosol generating device may have a size comparable to that of a conventional cigar or cigarette. The aerosol generating device may have a total length of about 25 mm to about 150 mm. The aerosol generating device may have an outer diameter of about 5 mm to about 30 mm.

[0058] The control circuit may further include a smoke detector in fluid communication with the airflow passage. The device may be configured with a heating element to activate the smoke. Advantageously, this may reduce energy consumption from the battery and ensure that aerosol is only generated when desired by the user.

[0059] The air inlet may be defined in a side wall of the device. The air outlet may be defined in an end wall of the device. The air outlet may be defined in a proximal end wall of the device. Advantageously, an air outlet defined in the proximal end wall of the device means that a cartridge comprising a mouthpiece can be simply coupled to the proximal end wall and therefore to the air outlet. The side wall of the device may extend perpendicular to the end wall of the device.

[0060] According to a third embodiment of the present disclosure, there is provided an aerosol generation system. The aerosol generation system may include a cartridge. The cartridge may include an aerosol-forming substrate. The cartridge may include a reservoir for containing the aerosol-forming substrate. The aerosol-forming substrate may be in fluid communication with a wicking material. The wicking material may form part of an outer surface of the cartridge.

[0061] The aerosol generating system may comprise an aerosol generating device. The aerosol generating system may comprise an aerosol generating device according to a second embodiment of the present disclosure. The aerosol generating device may comprise a heater assembly. The aerosol generating device may comprise a heater assembly according to a first embodiment of the present disclosure. The heater assembly may comprise a heating element. The heater assembly may further comprise a first electrical contact in electrical contact with a first end of the heating element. The heater assembly may further comprise a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact.

[0062] The heating element may comprise a plurality of heating portions. The heating element may further comprise at least one mounting portion. The at least one mounting portion may be positioned between the heating portions along the continuous electrical path.

[0063] The heater assembly may include a frame. The frame may include an opening. The frame may include an opening in a first plane.

[0064] The heating element may be fixed to the frame. Each heating portion may be within an opening. Each heating portion may be above an opening. Each heating portion may be separated from the frame by at least one mounting portion.

[0065] The cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path may be smaller than the cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path.

[0066] The aerosol generating system may comprise a system airflow passage defined between the system air inlet and the system air outlet. Particularly, as in the second embodiment, the aerosol generating device may further comprise an airflow passage defined between the air inlet and the air outlet. The system airflow passage may comprise the device airflow passage. The system air inlet may comprise the device air inlet. The system air outlet may comprise the device air outlet. The device airflow passage may be in fluid communication with the heating element. Particularly, the device airflow passage may be in fluid communication with a first side of the heating element. The system airflow passage may pass through a heater assembly. Particularly, the device airflow passage may pass through the heater assembly. The heater assembly may comprise a heater assembly airflow passage between the heater assembly air inlet and the heater assembly air outlet. The device air inlet may comprise a heater assembly air inlet. The system airflow passage may comprise a heater assembly airflow passage. Particularly, the device airflow passage may comprise a heater assembly airflow passage.

[0067] The aerosol generating device may further include a power source. The power source may be in electrical contact with the first electrical contact and the second electrical contact. The power source may be configured to supply power to the heating element. The aerosol generating device may further include a control circuit. The control circuit may be configured to control the supply of power from the power source to the heating element. Thus, advantageously, the power supplied to the heating element may be varied based on usage behavior.

[0068] The cartridge may be reversibly connectable to the aerosol generating device. The cartridge may be reversibly connectable to the aerosol generating device such that the wicking material is in direct contact with the heating element when the cartridge is connected to the device. Advantageously, the reversible connectability of the cartridge to the aerosol generating device means that when the cartridge is emptied or damaged, it can be discarded and replaced with a new cartridge. This can have cost savings and environmental benefits, as fewer components are discarded. The wicking element may have a cross-sectional area equal to the cross-sectional area of the opening. The wicking element may have a cross-sectional shape approximately the same as the cross-sectional shape of the opening.

[0069] The airflow passage of the aerosol generating device may be in fluid communication with a first side of the heating element. When the cartridge is coupled to the device, the wicking material may be in direct contact with a second side of the heating element. The first side of the heating element may be opposite the second side of the heating element.

[0070] The cartridge may further include a cartridge airflow passage defined between the cartridge air inlet and the cartridge air outlet.

[0071] The cartridge may further comprise a removable seal covering a portion of the cartridge. In particular, the cartridge may further comprise a removable seal covering the wicking element. The removable seal may be configured to be removed by a user.

[0072] When the cartridge is coupled to a device, the cartridge air inlet may be in fluid communication with the air outlet of the device.

[0073] The cartridge air outlet may comprise a mouthpiece.

[0074] The aerosol generating system may be a handheld aerosol generating system configured to allow a user to draw on a mouthpiece to draw aerosol through the cartridge air outlet. The aerosol generating system may have a size comparable to a conventional cigar or cigarette. The aerosol generating system may have a total length of about 25 mm to about 150 mm. The aerosol generating system may have an outer diameter of about 5 mm to about 30 mm.

[0075] The aerosol-forming substrate may be a liquid. In particular, the aerosol-forming substrate may be a liquid at standard temperature and pressure. Advantageously, this ensures that the liquid aerosol-forming substrate can be easily transferred from the reservoir to the wicking element and then to the heating element when the system is used at standard temperature and pressure. The aerosol-forming substrate may be a liquid at room temperature. The aerosol-forming substrate may be in another condensed form, such as a solid, at room temperature, or in another condensed form, such as a gel, at room temperature. The volatile compound may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may contain both liquid and solid components. The liquid aerosol-forming substrate may contain nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt matrix. The liquid aerosol-forming substrate may comprise a plant-derived material. The liquid aerosol-forming substrate may contain tobacco. The liquid aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may comprise a homogenized tobacco material. The liquid aerosol-forming substrate may comprise a non-tobacco-containing material.The liquid aerosol-forming substrate may comprise a homogenized plant-derived material.

[0076] The liquid aerosol-forming substrate may contain one or more aerosol formers. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense, stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the system. Examples of suitable aerosol formers include glycerin and propylene glycol. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (e.g., dimethyl dodecanedioate, dimethyl tetradecanedioate). The liquid aerosol-forming substrate may contain water, solvents, ethanol, plant extracts, and natural or artificial flavors. The liquid aerosol-forming substrate may contain nicotine and at least one aerosol former. The aerosol former may be glycerin or propylene glycol. The aerosol former may include both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of from about 0.5% to about 10%, for example about 2%.

[0077] According to a fourth embodiment of the present disclosure, there is provided a cartridge for an aerosol generation system. The cartridge may comprise an aerosol-forming substrate. The cartridge may comprise the aerosol-forming substrate as described in relation to the third embodiment. The aerosol-forming substrate may be in fluid communication with a wicking material.

[0078] The cartridge may include a heater assembly. The cartridge may include a heater assembly according to the first embodiment of the present disclosure. The cartridge may be configured to be coupled to an aerosol generating device. The heater assembly may be coupleable to and separable from the cartridge body. The heater assembly may include a heating element. The heater assembly may include a first electrical contact in electrical contact with a first end of the heating element. The heater assembly may include a second electrical contact in electrical contact with a second end of the heating element. The heating element may provide a continuous electrical path between the first electrical contact and the second electrical contact. The heating element may include a plurality of heating portions. The heating element may include at least one mounting portion positioned between the heating portions along the continuous electrical path. The heater assembly may include a frame. The frame may include openings in the first plane. The heating element may be fixed to the frame. Each heating portion may be within the opening. Each heating portion may be above the opening. Each heating portion may be separated from the frame by at least one mounting portion. A cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path may be smaller than a cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path. The heater assembly may form a portion of an exterior surface of the cartridge. The wicking material may be in contact with the heating element.

[0079] The cartridge may further include a cartridge airflow passage. The cartridge airflow passage may be defined between the cartridge air inlet and the cartridge air outlet. The cartridge airflow passage may be in fluid communication with the heating element. In particular, the cartridge airflow passage may be in fluid communication with a first side of the heating element. The cartridge airflow passage may pass through the heater assembly. The heater assembly may include a heater assembly airflow passage between the heater assembly air inlet and the heater assembly air outlet. The cartridge air inlet may include a heater assembly air inlet.

[0080] The cartridge may be configured to be coupled to an aerosol generating device. The cartridge may be configured to be coupled to an aerosol generating device such that the cartridge air inlet is aligned with the device air outlet of the aerosol generating device.

[0081] The cartridge air outlet may comprise a mouthpiece.

[0082] The aerosol-forming substrate may be a liquid. In particular, the aerosol-forming substrate may be a liquid at standard temperature and pressure. Advantageously, this ensures that the liquid aerosol-forming substrate can be easily transferred from the reservoir to the wicking element and then to the heating element when the system is used at standard temperature and pressure.

[0083] As used herein, the term "heating element" refers to an element of a heater assembly that is configured to be heated. For example, the term "heating element" may refer to an element that is configured for at least a portion of the element to be heated to at least 50, 100, 150, 200, 250, or 300 degrees Celsius.

[0084] As used herein, the term "coupled or coupleable" is used to mean that the cartridge and device can be coupled to and decoupled from each other without significant damage to either the device or the cartridge.

[0085] As used herein, the term "serpentine" is used to define a shape of a path that includes at least one curve or bend of approximately 180 degrees in the path, such that a first region of the shape lies along a second region of the shape when viewed perpendicular to the plane of the path. Thus, the shape may resemble a single Latin letter "S" or multiple Latin letter "S"s joined end-to-end.

[0086] As used herein, the terms "air inlet" and "air outlet" are used to describe one or more openings through which air may be drawn into and out of a heater assembly, aerosol generation system, cartridge or component or portion of a component of an aerosol generating device, respectively.

[0087] As used herein with respect to the present invention, the term "aerosol" is used to describe a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets in a gas. Aerosols can be visible or invisible. Aerosols may include vapors of substances that are normally liquids or solids at room temperature, as well as solid particulates, or liquid droplets, or a combination of solid particulates and liquid droplets.

[0088] As used herein, "aerosol-generating system" means a system that generates an aerosol from one or more aerosol-forming substrates.

[0089] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of releasing volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. [Example]

[0090] 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 features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.

[0091] Example 1 1. A heater assembly for an aerosol generating device, the heater assembly comprising: heating element, a first electrical contact in electrical contact with the first end of the heating element; and a second electrical contact in electrical contact with a second end of the heating element, the heating element comprising a second electrical contact providing a continuous electrical path between the first electrical contact and the second electrical contact; the heating element comprises a plurality of heating portions and at least one mounting portion positioned between the heating portions along a continuous electrical path; a frame having an opening in a first plane; the heating element is secured to the frame, and each heating portion is within or over an opening and is separated from the frame by at least one mounting portion; A heater assembly in which the cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path is less than the cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path. Example 2. 10. The heater assembly of example 1, wherein the plurality of heating portions and the at least one mounting portion are all integrally formed. Example 3 3. The heater assembly of any one of claims 1 to 2, wherein each mounting portion is directly connected to exactly two heating portions. Example 4. 10. A heater assembly according to any preceding claim, wherein each heating portion is directly connected to exactly two mounting portions, or to exactly one mounting portion and either the first electrical contact or the second electrical contact. Example 5. 5. The heater assembly of any of Examples 1-4, wherein each heating portion has a first width in a first direction, the first direction optionally being perpendicular to the direction of the continuous electrical path when the direction of the continuous electrical path is defined by each heating portion, and each mounting portion has a second width in the first direction, the second width being greater than the first width. Example 6 6. The heater assembly of example 5, wherein a ratio of the first width to the second width is between 1 / 20 and 1 / 2. Example 7 7. The heater assembly of example 6, wherein a ratio of the first width to the second width is between 1 / 10 and 1 / 4. Example 8 8. The heater assembly of example 5, 6, or 7, wherein the first width is between 0.1 millimeters and 2 millimeters. Example 9. 9. The heater assembly of example 8, wherein the first width is between 0.2 millimeters and 1 millimeter. Example 10. 10. The heater assembly of example example 9, wherein the first width is between 0.2 millimeters and 0.5 millimeters. Example 11 The heater assembly of any one of Examples 5 to 10, wherein the heating element has a thickness in at least one direction perpendicular to the first direction. Example 12 12. The heater assembly of example 11, having a thickness of 0.02 millimeters to 0.5 millimeters. Example 13 13. The heater assembly of example 12, wherein the thickness is between 0.05 millimeters and 0.3 millimeters. Example 14. A heater assembly described in any of Examples 1 to 13, wherein the electrical resistance per unit length in the direction of the conductive path of the multiple heating portions is greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting portion. Example 15. 14. The heater assembly of any one of Examples 1 to 13, wherein the electrical resistance of each heating portion is higher than the electrical resistance of each mounting portion. Example 16. 16. The heater assembly of any of Examples 1-15, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the plurality of heating portions increases above the temperature of the at least one mounting portion. Example 17. The heater assembly of any one of Examples 1 to 16, wherein the heating element is serpentine shaped. Example 18. 18. The heater assembly of any one of Examples 1-17, wherein the heating element comprises stainless steel. Example 19. 19. The heater assembly of any of Examples 1-18, wherein the heating element comprises a ferrimagnetic or ferromagnetic material. Example 20. 20. The heater assembly of any one of Examples 1-19, wherein the heating element is coated with a corrosion-resistant material. Example 21. 21. The heater assembly of any one of Examples 1-20, wherein the heating element is coated with a ceramic material. Example 22. The heater assembly of any one of Examples 1-21, wherein the heating element is substantially flat. Example 23. 23. The heater assembly of any one of Examples 1-22, wherein the total resistance of the heating element is between 0.1 ohms and 5 ohms. Example 24. 24. The heater assembly of example embodiment 23, wherein the total resistance of the heating element is between 0.2 ohms and 1.5 ohms. Example 25. 25. The heater assembly of any of Examples 1-24, wherein the heating element and the first and second electrical contacts are integrally formed. Example 26. The heater assembly of any of Examples 1-25, wherein the heating element and the first and second electrical contacts are formed of the same material. Example 27. 27. The heater assembly of any of Examples 1-26, wherein the opening is substantially square or rectangular. Example 28. The heater assembly of any of Examples 1-27, wherein the opening is substantially circular. Example 29. The heater assembly of any of Examples 1-28, wherein the frame is electrically insulating. Example 30. 30. The heater assembly of example example 29, wherein the frame has a thermal conductivity of 1 W / mK or less. Example 31. 31. The heater assembly of example 29 or 30, wherein the frame comprises a heat resistant polymer. Example 32. 32. The heater assembly of any of Examples 29-31, wherein the frame comprises polyetheretherketone (PEEK). Example 33. 31. The heater assembly of example 29 or 30, wherein the frame comprises ceramic. Example 34. 34. The heater assembly of example embodiment 33, wherein the frame comprises alumina. Example 35. 34. The heater assembly of example embodiment 33, wherein the frame comprises zirconia. Example 36. The heater assembly of any of Examples 1-35, wherein the frame is overmolded over the section of the heating element. Example 37. 37. The heater assembly of example embodiment 36, wherein the frame is overmolded onto the mounting section of the at least one mounting portion. Example 38. The heater assembly of any of Examples 1-37, wherein the frame is overmolded over at least a mounting section of the first electrical contact and at least a section of the second electrical contact. Example 39. The heater assembly of any of Examples 1-35, wherein the frame comprises an upper element and a lower element. Example 40. 40. The heater assembly of example example 39, wherein the upper and lower elements comprise press-fit elements such that the upper and lower elements can be joined together by a press fit. Example 41. 40. The heater assembly of example example 39, wherein the upper and lower elements comprise snap-fit elements such that the upper and lower elements can be joined together by a snap fit. Example 42. 42. The heater assembly of claim 40 or 41, wherein at least the mounting section of the at least one mounting portion is located between the upper element and the lower element when the upper element and the lower element are joined together. Example 43. A heater assembly described in any of Examples 40-42, wherein when the upper element and the lower element are joined together, at least a mounting section of the first electrical contact and at least a section of the second electrical contact are located between the upper element and the lower element. Example 44. 44. The heater assembly of any of Examples 1-43, wherein the opening has a cross-sectional area in the first plane of between 1 square millimeter and 1000 square millimeters. Example 45. 45. The heater assembly of example embodiment 44, wherein the opening has a cross-sectional area in the first plane of between 2 square millimeters and 200 square millimeters. Example 46. 46. The heater assembly of example embodiment 45, wherein the opening has a cross-sectional area in the first plane of between 4 square millimeters and 50 square millimeters. Example 47. 47. The heater assembly of any one of Examples 1-46, wherein the heating element further comprises at least one thermally insulating portion, and each mounting portion is separated from the frame by one thermally insulating portion. Example 48. 48. The heater assembly of Example 47, wherein each heating section is connected to the frame via at least one thermally insulating section. Example 49. 49. The heater assembly of embodiment 47 or 48, wherein the plurality of heating portions, at least one mounting portion, and at least one thermal insulating portion are all integrally formed. Example 50. The heater assembly of any of Examples 47-49 when dependent on Example 5, wherein each thermally insulating portion has a third width in the first direction, the third width being smaller than the second width. Example 51. 51. The heater assembly of Example 50, wherein the ratio of the third width to the second width is 1 / 10 to 2 / 3. Example 52. 52. The heater assembly of Example 51, wherein the ratio of the third width to the second width is 1 / 5 to 1 / 3. Example 53. 53. The heater assembly of any of Examples 50-52, wherein the third width is approximately equal to the first width. Example 54. A heater assembly described in any of Examples 47 to 53, wherein the thermal resistance across each mounting portion between adjacent heating portions and adjacent thermal insulation portions is lower than the thermal resistance across each thermal insulation portion between adjacent mounting portions and the frame. Example 55. 55. The heater assembly of any of Examples 1-54, wherein each heating portion includes a radius of curvature perpendicular to the first plane. Example 56. The heater assembly of any one of Examples 1 to 55, wherein the heating element comprises an elastic material. Example 57. 57. A heater assembly according to any one of Examples 1 to 56, wherein the frame has an upper surface parallel to a first plane, and at least a first portion of the heating element is recessed a first distance from the upper surface of the frame. Example 58. 58. The heater assembly of Example 57, wherein the first distance is 0.2 mm to 5 mm. Example 59. 59. The heater assembly of example 57 or 58, wherein the mounting section of at least one mounting portion is recessed a first distance from the top surface of the frame. Example 60. 60. The heater assembly of any of Examples 57-59, wherein at least a second portion of the heating element coincides with a plane formed by the top surface of the frame. Example 61. 60. The heater assembly of any of Examples 57-59, wherein the entire heating element is recessed from the top surface of the frame by a first distance. Example 62. A heater assembly described in any of Examples 57-61, wherein the frame has a lower surface parallel to the first plane, and at least a first portion of the heating element is recessed from the lower surface of the frame by a second distance. Example 63. 63. The heater assembly of example embodiment 62, wherein the second distance is 0.2 mm to 5 mm. Example 64. 64. The heater assembly of embodiment 62 or 63, wherein the mounting section of at least one mounting portion is recessed from the underside of the frame by a second distance. Example 65. 65. The heater assembly of any of Examples 1-64, further comprising a support structure, the frame at least partially enclosing the support structure, and the support structure comprising a support structure opening. Example 66. 66. The heater assembly of example 65, wherein at least a portion of the heating element is within or over the support structure opening. Example 67. 67. The heater assembly of embodiment 66, wherein the plurality of heating portions are within or above the support structure opening. Example 68. 68. The heater assembly of any of Examples 65-67, wherein the support structure has an upper support structure surface parallel to the first plane, and at least a portion of the heating element is coplanar with the upper support structure surface. Example 69. 69. The heater assembly of Example 68, wherein the plurality of heating portions are flush with the upper support structure surface. Example 70. 70. The heater assembly of claim 68 or 69, wherein each mounting portion comprises a first section and a second section, each first section being substantially coplanar with the upper support structure surface, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not coplanar with the upper support structure surface. Example 71. 71. The heater assembly of embodiment 70, wherein each second section extends in a direction perpendicular to the upper support structure surface. Example 72. 72. The heater assembly of example 70 or 71, wherein each second section is positioned between the frame and the support structure. Example 73. A heater assembly described in any of Examples 68 to 72, wherein both the first and second electrical contacts comprise a first electrical contact section and a second electrical contact section, both first electrical contact sections being substantially flush with the upper support structure surface, and both second electrical contact sections extending from the upper support structure surface toward the second plane. Example 74. 74. The heater assembly of embodiment 73, wherein both second electrical contact sections extend in a direction perpendicular to the upper support structure surface. Example 75. 75. The heater assembly of example 73 or 74, wherein both second electrical contact sections are positioned between the frame and the support structure. Example 76. 76. The heater assembly of any of Examples 68-75, wherein the frame has an upper surface that is flush with the upper support structure surface. Example 77. A heater assembly described in any of Examples 68 to 76, wherein the frame has a lower frame surface, the support structure has a lower support structure surface that is flush with the lower surface of the frame, and each of the first and second electrical contacts further has a third electrical contact section, and both of the third electrical contact sections are substantially flush with the lower surface of the frame. Example 78. 78. The heater assembly of any one of Examples 74-77, wherein the plurality of heating portions are flush with the top surface of the frame. Example 79. An aerosol generating device, comprising: A heater assembly, comprising: heating element, a first electrical contact in electrical contact with the first end of the heating element; and a second electrical contact in electrical contact with a second end of the heating element, the heating element comprising a second electrical contact providing a continuous electrical path between the first electrical contact and the second electrical contact; the heating element comprises a plurality of heating portions and at least one mounting portion positioned between the heating portions along a continuous electrical path; a frame having an opening in a first plane; the heating element is secured to the frame, and each heating portion is within or over an opening and is separated from the frame by at least one mounting portion; a heater assembly, wherein a cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path is less than a cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path; an airflow passage defined between the air inlet and the air outlet, the airflow passage being in fluid communication with the heating element; a power source in electrical contact with the first and second electrical contacts and 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 heating element. Example 80. 80. The aerosol generating device of Example 79, wherein the aerosol generating device is a handheld aerosol generating device. Example 81. An aerosol generating device as described in Example 79 or 80, wherein the control circuit further comprises a smoke detector in fluid communication with the airflow passage, and the device is configured such that the heating element is smoke-activated. Example 82. An aerosol generating device according to any one of Examples 79 to 81, wherein the air inlet is defined in a side wall of the device. Example 83. 83. An aerosol generating device as described in Example 82, wherein the air outlet is defined in an end wall of the device. Example 84. 84. The aerosol generating device of Example 83, wherein the side wall of the device extends perpendicular to the end wall of the device. Example 85. An aerosol generating device according to any one of Examples 79 to 84, wherein the plurality of heating portions and at least one mounting portion are all integrally formed. Example 86. An aerosol generating device described in any of Examples 79 to 85, wherein each mounting part is directly connected to exactly two heating parts. Example 87. An aerosol generating device described in any of Examples 79 to 86, wherein each heating portion is directly connected to exactly two mounting portions, or exactly one mounting portion, and either the first electrical contact or the second electrical contact. Example 88. An aerosol generating device described in any of Examples 79 to 87, wherein each heating portion has a first width in a first direction, each mounting portion has a second width in the first direction, and the second width is greater than the first width. Example 89. 89. The aerosol generating device of Example 88, wherein the ratio of the first width to the second width is 1 / 20 to 1 / 2. Example 90. 89. The aerosol generating device of Example 89, wherein the ratio of the first width to the second width is 1 / 10 to 1 / 4. Example 91. An aerosol generating device as described in Example 88, 89, or 90, wherein the first width is 0.1 millimeters to 2 millimeters. Example 92. 92. The aerosol generating device of Example 91, wherein the first width is 0.2 millimeters to 1 millimeter. Example 93. 93. The aerosol generating device of Example 92, wherein the first width is 0.2 millimeters to 0.5 millimeters. Example 94. The aerosol generating device according to any one of Examples 79 to 93, wherein the heating element has a thickness in at least one direction perpendicular to the first direction. Example 95. The aerosol generating device described in Example 93, having a thickness of 0.02 millimeters to 0.5 millimeters. Example 96. The aerosol generating device of Example 95, having a thickness of 0.05 millimeters to 0.3 millimeters. Example 97. An aerosol generating device described in any of Examples 79 to 96, wherein the electrical resistance per unit length in the direction of the conductive path of multiple heating parts is greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting part. Example 98. 98. The aerosol generating device according to any one of Examples 79 to 97, wherein the electrical resistance of each heating part is higher than the electrical resistance of each mounting part. Example 99. An aerosol generating device described in any of Examples 79 to 98, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating portions increases above the temperature of at least one mounting portion. Example 100. 99. The aerosol generator according to any one of Examples 79 to 99, wherein the heating element has a serpentine shape. Example 101. 101. The aerosol generator of any one of Examples 79 to 100, wherein the heating element comprises stainless steel. Example 102. 102. The aerosol generating apparatus of any one of Examples 79 to 101, wherein the heating element comprises a ferrimagnetic or ferromagnetic material. Example 103. 103. The aerosol generating apparatus of any one of Examples 79 to 102, wherein the heating element is coated with a corrosion-resistant material. Example 104. The aerosol generating apparatus of any one of Examples 79 to 103, wherein the heating element is coated with a ceramic material. Example 105. The aerosol generating device of any one of Examples 79 to 104, wherein the heating element is substantially flat. Example 106. The aerosol generating apparatus according to any one of Examples 79 to 105, wherein the total resistance of the heating element is 0.1 ohms to 5 ohms. Example 107. The aerosol generating device of Example 106, wherein the total resistance of the heating element is 0.2 ohms to 1.5 ohms. Example 108. The aerosol generating device of any of Examples 79 to 107, wherein the heating element and the first and second electrical contacts are integrally formed. Example 109. An aerosol generating device according to any one of Examples 79 to 108, wherein the heating element and the first and second electrical contacts are formed from the same material. Example 110. The aerosol generating device according to any one of Examples 79 to 109, wherein the opening is substantially square or rectangular. Example 111. The aerosol generating device according to any one of Examples 79 to 110, wherein the opening is substantially circular. Example 112. The aerosol generating apparatus according to any one of Examples 79 to 111, wherein the frame is electrically insulating. Example 113. An aerosol generating device as described in Example 112, wherein the frame has a thermal conductivity of 1 W / mk or less. Example 114. 114. The aerosol generating device of Examples 112 or 113, wherein the frame comprises a heat-resistant polymer. Example 115. 115. The aerosol generating device of any one of Examples 112 to 114, wherein the frame comprises polyetheretherketone (PEEK). Example 116. An aerosol generating device according to any one of Examples 112 to 113, wherein the frame comprises ceramic. Example 117. 117. The aerosol generating device of claim 116, wherein the frame comprises alumina. Example 118. 117. The aerosol generating device of example 116, wherein the frame comprises zirconia. Example 119. An aerosol generating device described in any of Examples 79 to 118, wherein the frame is overmolded onto the heating element section. Example 120. An aerosol generating device as described in Example 119, wherein the frame is overmolded onto the mounting section of at least one mounting portion. Example 121. An aerosol generating device described in any of Examples 79 to 120, wherein the frame is overmolded onto at least an attachment section of the first electrical contact and at least a section of the second electrical contact. Example 122. An aerosol generating device according to any one of Examples 79 to 118, wherein the frame comprises an upper element and a lower element. Example 123. 123. The aerosol generating device of Example 122, wherein the upper and lower elements comprise press-fit elements such that the upper and lower elements can be joined together by press-fitting. Example 124. 123. An aerosol generating device as described in Example 122, wherein the upper and lower elements comprise snap-fit elements such that the upper and lower elements can be joined together by a snap fit. Example 125. An aerosol generating device as described in Example 123 or 124, wherein at least the mounting section of at least one mounting portion is located between the upper element and the lower element when the upper element and the lower element are joined together. Example 126. An aerosol generating device described in any of Examples 123 to 125, wherein at least an attachment section of the first electrical contact and at least a section of the second electrical contact are located between the upper element and the lower element when the upper element and the lower element are joined together. Example 127. 127. The aerosol generating device of any one of Examples 79 to 126, wherein the opening has a cross-sectional area in the first plane of 1 square millimeter to 1000 square millimeters. Example 128. 128. The aerosol generating device of Example 127, wherein the opening has a cross-sectional area in the first plane of 2 square millimeters to 200 square millimeters. Example 129. 129. The aerosol generating device of Example 128, wherein the opening has a cross-sectional area in the first plane of 4 square millimeters to 50 square millimeters. Example 130. An aerosol generating device described in any of Examples 79 to 129, wherein the heating element further comprises at least one thermally insulating part, and each mounting part is separated from the frame by one thermally insulating part. Example 131. An aerosol generating device as described in Example 130, wherein each heating portion is connected to the frame via at least one thermal insulating portion. Example 132. An aerosol generating device as described in Example 130 or 131, wherein the multiple heating portions, at least one mounting portion, and at least one thermal insulation portion are all integrally formed. Example 133. An aerosol generating device described in any of Examples 130 to 132 when dependent on Example 88, wherein each thermal insulating portion has a third width in the first direction, and the third width is smaller than the second width. Example 134. 134. The aerosol generating device of Example 133, wherein the ratio of the third width to the second width is 1 / 10 to 2 / 3. Example 135. 135. The aerosol generating device of Example 134, wherein the ratio of the third width to the second width is 1 / 5 to 1 / 3. Example 136. 136. The heater assembly of any of Examples 133-135, wherein the third width is approximately equal to the first width. Example 137. An aerosol generating device described in any of Examples 130 to 136, wherein the thermal resistance across each mounting portion between adjacent heating portions and adjacent thermal insulation portions is lower than the thermal resistance across each thermal insulation portion between adjacent mounting portions and the frame. Example 138. 138. The aerosol generating device of any one of Examples 79 to 137, wherein each heating portion comprises a radius of curvature perpendicular to the first plane. Example 139. The aerosol generating device of any of Examples 79 to 138, wherein the heating element comprises an elastic material. Example 140. An aerosol generating device described in any of Examples 79 to 139, wherein the frame has an upper surface parallel to the first plane, and at least a first portion of the heating element is recessed a first distance from the upper surface of the frame. Example 141. 141. The aerosol generating device of Example 140, wherein the first distance is 0.2 mm to 5 mm. Example 142. An aerosol generating device as described in Example 140 or 141, wherein the mounting section of at least one mounting portion is recessed a first distance from the top surface of the frame. Example 143. 143. The aerosol generating device of any one of Examples 140 to 142, wherein at least the second portion of the heating element coincides with a plane formed by the upper surface of the frame. Example 144. 143. The aerosol generating apparatus of any one of Examples 140 to 142, wherein the entire heating element is recessed from the top surface of the frame by a first distance. Example 145. An aerosol generating device described in any of Examples 140 to 144, wherein the frame has a lower surface parallel to the first plane, and at least a first portion of the heating element is recessed from the lower surface of the frame by a second distance. Example 146. The aerosol generating device of Example 145, wherein the second distance is 0.2 mm to 5 mm. Example 147. An aerosol generating device as described in Example 145 or 146, wherein the mounting section of at least one mounting portion is recessed a second distance from the lower surface of the frame. Example 148. An aerosol generating device described in any of Examples 79 to 147, further comprising a support structure, wherein the frame at least partially surrounds the support structure, and the support structure has a support structure opening. Example 149. An aerosol generating device as described in Example 148, wherein at least a portion of the heating element is within or above the support structure opening. Example 150. An aerosol generating device as described in Example 149, wherein multiple heating portions are located within or above the support structure opening. Example 151. An aerosol generating device described in any of Examples 148 to 150, wherein the support structure has an upper support structure surface parallel to the first plane, and at least a portion of the heating element is flush with the upper support structure surface. Example 152. An aerosol generating device as described in Example 151, wherein the multiple heating portions are flush with the upper support structure surface. Example 153. An aerosol generating device as described in Example 151 or 152, wherein each mounting portion has a first section and a second section, each first section being substantially flush with the upper support structure surface, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not flush with the upper support structure surface. Example 154. An aerosol generating device as described in Example 153, wherein each second section extends in a direction perpendicular to the surface of the upper support structure. Example 155. An aerosol generating device as described in Example 153 or 154, wherein each second section is positioned between the frame and the support structure. Example 156. An aerosol generating device described in any of Examples 151 to 155, wherein both the first and second electrical contacts comprise a first electrical contact section and a second electrical contact section, both first electrical contact sections being substantially flush with the upper support structure surface, and both second electrical contact sections extending from the upper support structure surface toward the second plane. Example 157. An aerosol generating device as described in Example 156, wherein both second electrical contact sections extend in a direction perpendicular to the upper support structure surface. Example 158. An aerosol generating device as described in Example 156 or 157, wherein both second electrical contact sections are positioned between the frame and the support structure. Example 159. An aerosol generating device described in any of Examples 151 to 158, wherein the frame has an upper surface that is flush with the upper support structure surface. Example 160. An aerosol generating device described in any of Examples 151 to 159, wherein the frame has a lower frame surface, the support structure has a lower support structure surface that is flush with the lower surface of the frame, and each of the first and second electrical contacts further has a third electrical contact section, and both third electrical contact sections are substantially flush with the lower surface of the frame. Example 161. 161. The aerosol generating device according to any one of Examples 157 to 160, wherein the plurality of heating portions are flush with the upper surface of the frame. Example 162. 1. An aerosol generating system comprising: A cartridge, comprising: an aerosol-forming substrate in fluid communication with the wicking material, a cartridge comprising an aerosol-forming substrate, the wicking material forming part of the outer surface of the cartridge; An aerosol generating device, comprising: A heater assembly, comprising: heating element, a first electrical contact in electrical contact with the first end of the heating element; and a second electrical contact in electrical contact with a second end of the heating element, the heating element comprising a second electrical contact providing a continuous electrical path between the first electrical contact and the second electrical contact; the heating element comprises a plurality of heating portions and at least one mounting portion positioned between the heating portions along a continuous electrical path; a frame having an opening in a first plane; the heating element is secured to the frame, and each heating portion is within or over an opening and is separated from the frame by at least one mounting portion; a heater assembly, wherein a cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path is less than a cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path; an airflow passage defined between the air inlet and the air outlet, the airflow passage being in fluid communication with the heating element; a power source in electrical contact with the first and second electrical contacts and configured to provide power to the heating element; a control circuit configured to control the supply of power from the power source to the heating element; and An aerosol generating system, wherein the cartridge is reversibly connectable to an aerosol generating device such that the wicking material is in direct contact with the heating element when the cartridge is connected to the device. Example 163. An aerosol generation system as described in Example 162, wherein the airflow passage is fluidly connected to a first side of the heating element and the wicking material is in direct contact with a second side of the heating element when the cartridge is coupled to the device. Example 164. An aerosol generation system as described in Example 162 or 163, wherein the cartridge further comprises a cartridge airflow passage defined between the cartridge air inlet and the cartridge air outlet. Example 165. An aerosol generation system as described in Example 164, wherein the cartridge air intake is fluidly connected to the air outlet of the device when the cartridge is coupled to the device. Example 166. An aerosol generation system as described in Example 164 or 165, wherein the cartridge air outlet is equipped with a mouthpiece. Example 167. 167. The aerosol-generating system of any of Examples 162 to 166, wherein the aerosol-forming substrate is liquid at standard temperature and pressure. Example 168. An aerosol generation system described in any of Examples 162 to 167, wherein multiple heating portions and at least one mounting portion are all integrally formed. Example 169. An aerosol generation system described in any of Examples 162 to 168, wherein each mounting portion is directly connected to exactly two heating portions. Example 170. An aerosol generation system described in any of Examples 162 to 169, wherein each heating portion is directly connected to exactly two mounting portions, or exactly one mounting portion, and either the first electrical contact or the second electrical contact. Example 171. An aerosol generation system described in any of Examples 162 to 170, wherein each heating portion has a first width in a first direction, each mounting portion has a second width in the first direction, and the second width is greater than the first width. Example 172. An aerosol generation system as described in Example 171, wherein the ratio of the first width to the second width is 1 / 20 to 1 / 2. Example 173. An aerosol generation system as described in Example 172, wherein the ratio of the first width to the second width is 1 / 10 to 1 / 4. Example 174. 174. The aerosol generation system of Example 171, 172, or 173, wherein the first width is between 0.1 millimeters and 2 millimeters. Example 175. An aerosol generation system as described in Example 174, wherein the first width is 0.2 millimeters to 1 millimeter. Example 176. An aerosol generation system as described in Example 175, wherein the first width is 0.2 millimeters to 0.5 millimeters. Example 177. An aerosol generating system described in any of Examples 162 to 176, wherein the heating element has a thickness in at least one direction perpendicular to the first direction. Example 178. The aerosol generating system of Example 177, having a thickness of 0.02 millimeters to 0.5 millimeters. Example 179. The aerosol generating system of Example 178, having a thickness of 0.05 millimeters to 0.3 millimeters. Example 180. An aerosol generating system described in any of Examples 162 to 179, wherein the electrical resistance per unit length in the direction of the conductive path of multiple heating portions is greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting portion. Example 181. An aerosol generating system described in any of Examples 162 to 180, wherein the electrical resistance of each heating portion is higher than the electrical resistance of each mounting portion. Example 182. An aerosol generation system described in any of Examples 162 to 181, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating portions increases above the temperature of at least one mounting portion. Example 183. The aerosol generating system of any of Examples 162 to 182, wherein the heating element has a serpentine shape. Example 184. The aerosol generating system of any of Examples 162-183, wherein the heating element comprises stainless steel. Example 185. An aerosol generating system according to any one of Examples 162 to 184, wherein the heating element comprises a ferrimagnetic or ferromagnetic material. Example 186. 186. The aerosol generating system of any one of Examples 162 to 185, wherein the heating element is coated with a corrosion-resistant material. Example 187. The aerosol generating system of any one of Examples 162 to 186, wherein the heating element is coated with a ceramic material. Example 188. An aerosol generating system described in any of Examples 162 to 187, wherein the heating element is substantially flat. Example 189. An aerosol generating system described in any of Examples 162 to 188, wherein the total resistance of the heating element is 0.1 ohms to 5 ohms. Example 190. An aerosol generation system as described in Example 189, wherein the total resistance of the heating element is 0.2 ohms to 1.5 ohms. Example 191. An aerosol generating system described in any of Examples 162 to 190, wherein the heating element and the first and second electrical contacts are integrally formed. Example 192. An aerosol generating system described in any of Examples 162 to 191, wherein the heating element and the first and second electrical contacts are formed from the same material. Example 193. An aerosol generation system described in any of Examples 162 to 192, wherein the opening is substantially square or rectangular. Example 194. An aerosol generating system described in any of Examples 162 to 193, wherein the opening is substantially circular. Example 195. The aerosol generating system of any of Examples 162 to 194, wherein the frame is electrically insulating. Example 196. An aerosol generation system as described in Example 195, wherein the frame has a thermal conductivity of 1 W / mk or less. Example 197. 197. The aerosol generating system of example 195 or 196, wherein the frame comprises a heat-resistant polymer. Example 198. 198. The aerosol generating system of any one of Examples 195-197, wherein the frame comprises polyetheretherketone (PEEK). Example 199. 197. The aerosol generating system of example 195 or 196, wherein the frame comprises ceramic. Example 200. 197. The aerosol generating system of example 195 or 196, wherein the frame comprises alumina. Example 201. 201. The aerosol generating system of example 200, wherein the frame comprises zirconia. Example 202. An aerosol generating system described in any of Examples 162 to 201, wherein the frame is overmolded onto the heating element section. Example 203. An aerosol generation system as described in Example 202, wherein the frame is overmolded onto the mounting section of at least one mounting portion. Example 204. An aerosol generation system described in any of Examples 162 to 203, wherein the frame is overmolded onto at least an attachment section of the first electrical contact and at least a section of the second electrical contact. Example 205. An aerosol generation system described in any of Examples 162 to 201, wherein the frame comprises an upper element and a lower element. Example 206. 206. The aerosol generation system of example 205, wherein the upper and lower elements comprise press-fit elements such that the upper and lower elements can be joined together by press-fitting. Example 207. An aerosol generation system as described in Example 205, wherein the upper element and the lower element have snap-fit elements such that the upper element and the lower element can be joined together by a snap fit. Example 208. An aerosol generation system as described in Example 206 or 207, wherein at least the mounting section of at least one mounting portion is located between the upper element and the lower element when the upper element and the lower element are joined together. Example 209. An aerosol generation system described in any of Examples 206 to 208, wherein at least an attachment section of the first electrical contact and at least a section of the second electrical contact are located between the upper element and the lower element when the upper element and the lower element are joined together. Example 210. An aerosol generation system according to any one of Examples 162 to 209, wherein the opening has a cross-sectional area in the first plane of 1 square millimeter to 1000 millimeters. Example 211. 211. The aerosol generation system of Example 210, wherein the opening has a cross-sectional area in the first plane of between 2 square millimeters and 200 square millimeters. Example 212. 212. The aerosol generation system of Example 211, wherein the opening has a cross-sectional area in the first plane of between 4 square millimeters and 50 square millimeters. Example 213. An aerosol generating system described in any of Examples 162 to 212, wherein the heating element further comprises at least one thermally insulating portion, and each mounting portion is separated from the frame by one thermally insulating portion. Example 214. An aerosol generation system as described in Example 213, wherein each heating element is connected to the frame via at least one thermal insulating element. Example 215. An aerosol generation system as described in Example 213 or 214, wherein the multiple heating portions, at least one mounting portion, and at least one thermal insulation portion are all integrally formed. Example 216. An aerosol generating system described in any of Examples 213 to 215 when dependent on Example 171, wherein each thermal insulating portion has a third width in the first direction, the third width being smaller than the second width. Example 217. An aerosol generation system as described in Example 216, wherein the ratio of the third width to the second width is 1 / 10 to 2 / 3. Example 218. An aerosol generation system as described in Example 217, wherein the ratio of the third width to the second width is 1 / 5 to 1 / 3. Example 219. 219. The aerosol generation system of any of Examples 216-218, wherein the third width is approximately equal to the first width. Example 220. An aerosol generating system described in any of Examples 213 to 219, wherein the thermal resistance across each mounting portion between adjacent heating portions and adjacent thermal insulation portions is lower than the thermal resistance across each thermal insulation portion between adjacent mounting portions and the frame. Example 221. An aerosol generation system described in any of Examples 162 to 220, wherein each heating portion includes a radius of curvature perpendicular to the first plane. Example 222. The aerosol generating system of any one of Examples 162 to 221, wherein the heating element comprises an elastic material. Example 223. An aerosol generating system described in any of Examples 162 to 222, wherein the frame has an upper surface parallel to a first plane, and at least a first portion of the heating element is recessed from the upper surface of the frame by a first distance. Example 224. 224. The aerosol generation system of Example 223, wherein the first distance is 0.2 mm to 5 mm. Example 225. An aerosol generation system described in Example 223 or 224, wherein the mounting section of at least one mounting portion is recessed a first distance from the top surface of the frame. Example 226. An aerosol generating system described in any of Examples 223 to 225, wherein at least a second portion of the heating element coincides with a plane formed by the upper surface of the frame. Example 227. An aerosol generating system according to any one of Examples 223 to 225, wherein the entire heating element is recessed from the top surface of the frame by a first distance. Example 228. An aerosol generating system described in any of Examples 223 to 227, wherein the frame has a lower surface parallel to the first plane, and at least a first portion of the heating element is recessed from the lower surface of the frame by a second distance. Example 229. The aerosol generation system of Example 228, wherein the second distance is 0.2 mm to 5 mm. Example 230. An aerosol generation system described in Example 228 or 229, wherein the mounting section of at least one mounting portion is recessed a second distance from the lower surface of the frame. Example 231. An aerosol generation system described in any of Examples 162 to 230, further comprising a support structure, wherein the frame at least partially surrounds the support structure, and the support structure has a support structure opening. Example 232. An aerosol generating system as described in Example 231, wherein at least a portion of the heating element is within or above the support structure opening. Example 233. An aerosol generation system as described in Example 232, wherein multiple heating portions are located within or above the support structure opening. Example 234. An aerosol generating system described in any of Examples 231 to 233, wherein the support structure has an upper support structure surface parallel to the first plane, and at least a portion of the heating element is flush with the upper support structure surface. Example 235. An aerosol generation system as described in Example 234, wherein the multiple heating portions are flush with the upper support structure surface. Example 236. An aerosol generation system as described in Example 234 or 235, wherein each mounting portion has a first section and a second section, each first section being substantially flush with the upper support structure surface, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not flush with the upper support structure surface. Example 237. An aerosol generation system as described in Example 236, wherein each second section extends in a direction perpendicular to the upper support structure surface. Example 238. An aerosol generation system as described in Example 236 or 237, wherein each second section is positioned between the frame and the support structure. Example 239. An aerosol generation system described in any of Examples 234 to 238, wherein both the first and second electrical contacts comprise a first electrical contact section and a second electrical contact section, both first electrical contact sections being substantially flush with the upper support structure surface, and both second electrical contact sections extending from the upper support structure surface toward the second plane. Example 240. An aerosol generation system as described in Example 239, wherein both second electrical contact sections extend in a direction perpendicular to the upper support structure surface. Example 241. An aerosol generation system as described in Example 239 or 240, wherein both second electrical contact sections are positioned between the frame and the support structure. Example 242. An aerosol generation system described in any of Examples 234 to 241, wherein the frame has an upper surface that is flush with the upper support structure surface. Example 243. An aerosol generation system described in any of Examples 234 to 242, wherein the frame has a lower frame surface, the support structure has a lower support structure surface that is flush with the lower surface of the frame, and each of the first and second electrical contacts further has a third electrical contact section, and both third electrical contact sections are substantially flush with the lower surface of the frame. Example 244. An aerosol generation system described in any of Examples 240 to 243, wherein the multiple heating portions are flush with the upper surface of the frame. Example 245. 1. A cartridge for an aerosol generation system, comprising: an aerosol-forming substrate in fluid communication with the wicking material; and A heater assembly, comprising: a heating element, wherein the wicking material is in contact with the heating element; a first electrical contact in electrical contact with the first end of the heating element; and a second electrical contact in electrical contact with a second end of the heating element, the heating element comprising a second electrical contact providing a continuous electrical path between the first electrical contact and the second electrical contact; the heating element comprises a plurality of heating portions and at least one mounting portion positioned between the heating portions along a continuous electrical path; a frame having an opening; the heating element is secured to the frame, and each heating portion is within or over an opening and is separated from the frame by at least one mounting portion; a heater assembly, wherein a cross-sectional area of each heating portion perpendicular to the direction of the continuous electrical path is smaller than a cross-sectional area of each mounting portion perpendicular to the direction of the continuous electrical path. Example 246. The cartridge described in Example 245, wherein the cartridge is configured to be reversibly connectable to and detachable from the aerosol generating device. Example 247. 247. The cartridge of example 245 or 246, further comprising a cartridge airflow passage defined between the cartridge air inlet and the cartridge air outlet. Example 248. The cartridge of Example 247, wherein the cartridge air outlet comprises a mouthpiece. Example 249. The cartridge of any of Examples 245 to 248, wherein the aerosol-forming substrate is liquid at standard temperature and pressure. Example 250. The cartridge of any of Examples 245-249, wherein the plurality of heating portions and at least one mounting portion are all integrally formed. Example 251. 251. The cartridge of any of Examples 245 to 250, wherein each mounting portion is directly connected to exactly two heating portions. Example 252. A cartridge described in any of Examples 245 to 251, wherein each heating portion is directly connected to exactly two mounting portions, or exactly one mounting portion, and either the first electrical contact or the second electrical contact. Example 253. A cartridge described in any of Examples 245 to 252, wherein each heating portion has a first width in a first direction, each mounting portion has a second width in the first direction, and the second width is greater than the first width. Example 254. 254. The cartridge of Example 253, wherein the ratio of the first width to the second width is 1 / 20 to 1 / 2. Example 255. 255. The cartridge of Example 254, wherein the ratio of the first width to the second width is 1 / 10 to 1 / 4. Example 256. 256. The cartridge of example 253, 254, or 255, wherein the first width is between 0.1 millimeters and 2 millimeters. Example 257. The cartridge of Example 256, wherein the first width is between 0.2 millimeters and 1 millimeter. Example 258. The cartridge of Example 257, wherein the first width is between 0.2 millimeters and 0.5 millimeters. Example 259. The cartridge of any of Examples 245 to 258, wherein the heating element has a thickness in at least one direction perpendicular to the first direction. Example 260. The cartridge of Example 259, having a thickness of 0.02 millimeters to 0.5 millimeters. Example 261. The cartridge of Example 260, having a thickness of 0.05 millimeters to 0.3 millimeters. Example 262. A cartridge described in any of Examples 245 to 261, wherein the electrical resistance per unit length in the direction of the conductive path of multiple heating portions is greater than the electrical resistance per unit length in the direction of the conductive path of at least one mounting portion. Example 263. The cartridge of any of Examples 245 to 262, wherein the electrical resistance of each heating portion is higher than the electrical resistance of each mounting portion. Example 264. A cartridge described in any of Examples 245 to 263, wherein the heater assembly is configured such that when a non-zero voltage is applied across the heating element between the first electrical contact and the second electrical contact, the temperature of the multiple heating portions increases above the temperature of at least one mounting portion. Example 265. The cartridge of any one of Examples 245 to 264, wherein the heating element has a serpentine shape. Example 266. The cartridge of any of Examples 245-265, wherein the heating element comprises stainless steel. Example 267. The cartridge of any of Examples 245-266, wherein the heating element comprises a ferrimagnetic or ferromagnetic material. Example 268. The cartridge of any of Examples 245 to 267, wherein the heating element is coated with a corrosion-resistant material. Example 269. The cartridge of any of Examples 245 to 268, wherein the heating element is coated with a ceramic material. Example 270. The cartridge of any of Examples 245 to 269, wherein the heating element is substantially flat. Example 271. The cartridge of any of Examples 245 to 270, wherein the total resistance of the heating element is 0.1 ohms to 5 ohms. Example 272. The cartridge of example 271, wherein the total resistance of the heating element is between 0.2 ohms and 1.5 ohms. Example 273. The cartridge of any of Examples 245 to 272, wherein the heating element and the first and second electrical contacts are integrally formed. Example 274. The cartridge of any of Examples 245-273, wherein the heating element and the first and second electrical contacts are formed of the same material. Example 275. The cartridge of any of Examples 245 to 274, wherein the opening is substantially square or rectangular. Example 276. The cartridge of any of Examples 245 to 274, wherein the opening is substantially circular. Example 277. The cartridge of any one of Examples 245 to 276, wherein the frame is electrically insulating. Example 278. The cartridge of Example 277, wherein the frame has a thermal conductivity of 1 W / mK or less. Example 279. The cartridge of example 277 or 278, wherein the frame comprises a heat-resistant polymer. Example 280. 279. The cartridge of any of Examples 277-279, wherein the frame comprises polyetheretherketone (PEEK). Example 281. 279. The cartridge of example 277 or 278, wherein the frame comprises ceramic. Example 282. The cartridge of example 281, wherein the frame comprises alumina. Example 283. 282. The cartridge of example 281, wherein the frame comprises zirconia. Example 284. The cartridge of any of Examples 245-283, wherein the frame is overmolded over the section of the heating element. Example 285. The cartridge of example 284, wherein the frame is overmolded onto the mounting section of at least one mounting portion. Example 286. The cartridge of any of Examples 245-285, wherein the frame is overmolded over at least a mounting section of the first electrical contact and at least a section of the second electrical contact. Example 287. The cartridge of any of Examples 245 to 283, wherein the frame comprises an upper element and a lower element. Example 288. The cartridge of example 287, wherein the upper and lower elements comprise press-fit elements such that the upper and lower elements can be joined together by a press fit. Example 289. The cartridge of example 287, wherein the upper and lower elements include snap-fit elements such that the upper and lower elements can be joined together by a snap fit. Example 290. 289. The cartridge of example 288 or 289, wherein at least the mounting section of the at least one mounting portion is located between the upper element and the lower element when the upper element and the lower element are coupled together. Example 291. A cartridge described in any of Examples 288 to 290, wherein at least an attachment section of the first electrical contact and at least a section of the second electrical contact are located between the upper element and the lower element when the upper element and the lower element are joined together. Example 292. The cartridge of any of Examples 245 to 291, wherein the opening has a cross-sectional area in the first plane of 1 square millimeter to 1000 square millimeters. Example 293. The cartridge of example 292, wherein the opening has a cross-sectional area in the first plane of between 9 square millimeters and 400 square millimeters. Example 294. The cartridge of Example 293, wherein the opening has a cross-sectional area in the first plane of between 16 square millimeters and 100 square millimeters. Example 295. The cartridge of any of Examples 245 to 294, wherein the heating element further comprises at least one thermally insulating portion, and each mounting portion is separated from the frame by one thermally insulating portion. Example 296. The cartridge of Example 295, wherein each heating portion is connected to the frame via at least one thermal insulating portion. Example 297. 297. A cartridge as described in example 295 or 296, wherein the plurality of heating portions, at least one mounting portion, and at least one thermal insulating portion are all integrally formed. Example 298. A cartridge described in any of Examples 295 to 297 when dependent on Example 253, wherein each thermal insulating portion has a third width in the first direction, the third width being smaller than the second width. Example 299. The cartridge of Example 298, wherein the ratio of the third width to the second width is 1 / 10 to 2 / 3. Example 300. 299. The cartridge of Example 299, wherein the ratio of the third width to the second width is 1 / 5 to 1 / 3. Example 301. The cartridge of any of Examples 298 to 300, wherein the third width is approximately equal to the first width. Example 302. A cartridge described in any of Examples 295 to 301, wherein the thermal resistance across each mounting portion between adjacent heating portions and adjacent thermal insulation portions is lower than the thermal resistance across each thermal insulation portion between adjacent mounting portions and the frame. Example 303. The cartridge of any of Examples 245 to 302, wherein each heating portion includes a radius of curvature perpendicular to the first plane. Example 304. The cartridge of any of Examples 245 to 303, wherein the heating element comprises an elastic material. Example 305. A cartridge described in any of Examples 245 to 304, wherein the frame has an upper surface parallel to the first plane, and at least a first portion of the heating element is recessed a first distance from the upper surface of the frame. Example 306. The cartridge of Example 305, wherein the first distance is 0.2 mm to 5 mm. Example 307. The cartridge of example 305 or 306, wherein the mounting section of at least one mounting portion is recessed a first distance from the top surface of the frame. Example 308. The cartridge of any of Examples 305-307, wherein at least a second portion of the heating element coincides with a plane formed by the top surface of the frame. Example 309. The cartridge of any of Examples 305 to 307, wherein the entire heating element is recessed from the top surface of the frame by a first distance. Example 310. The cartridge of any of Examples 305-309, wherein the frame includes a lower surface parallel to the first plane, and at least a first portion of the heating element is recessed from the lower surface of the frame by a second distance. Example 311. The cartridge of Example 310, wherein the second distance is 0.2 mm to 5 mm. Example 312. The cartridge of example 310 or 311, wherein the mounting section of at least one mounting portion is recessed from the underside of the frame by a second distance. Example 313. The cartridge of any of Examples 245-312, further comprising a support structure, wherein the frame at least partially surrounds the support structure, and wherein the support structure comprises a support structure opening. Example 314. The cartridge of example 313, wherein at least a portion of the heating element is within or above the support structure opening. Example 315. A cartridge as described in Example 314, wherein the multiple heating portions are within or above the support structure opening. Example 316. The cartridge of any of Examples 313-315, wherein the support structure comprises an upper support structure surface parallel to the first plane, and at least a portion of the heating element is coplanar with the upper support structure surface. Example 317. The cartridge of Example 316, wherein the plurality of heating portions are flush with the upper support structure surface. Example 318. A cartridge as described in Example 316 or 317, wherein each mounting portion comprises a first section and a second section, each first section being substantially flush with the upper support structure surface, and each second section extending from the upper support structure surface toward a second plane, the second plane being parallel to but not flush with the upper support structure surface. Example 319. The cartridge of Example 318, wherein each second section extends in a direction perpendicular to the upper support structure surface. Example 320. The cartridge of example 318 or 319, wherein each second section is positioned between the frame and the support structure. Example 321. A cartridge described in any of Examples 316 to 320, wherein both the first and second electrical contacts comprise a first electrical contact section and a second electrical contact section, both first electrical contact sections being substantially flush with the upper support structure surface, and both second electrical contact sections extending from the upper support structure surface toward the second plane. Example 322. The cartridge of example 321, wherein both second electrical contact sections extend in a direction perpendicular to the upper support structure surface. Example 323. The cartridge of example 321 or 322, wherein both second electrical contact sections are positioned between the frame and the support structure. Example 324. The cartridge of any of Examples 316-323, wherein the frame has an upper surface that is flush with the upper support structure surface. Example 325. A cartridge described in any of Examples 316 to 324, wherein the frame has a lower frame surface, the support structure has a lower support structure surface that is flush with the lower surface of the frame, and each of the first and second electrical contacts further has a third electrical contact section, and both of the third electrical contact sections are substantially flush with the lower surface of the frame. Example 326. The cartridge of any of Examples 324-325, wherein the plurality of heating portions are flush with the upper surface of the frame.

[0092] Features of one aspect or embodiment of the invention may be applied to other aspects or embodiments of the invention. [Brief explanation of the drawings]

[0093] The embodiments will now be further described with reference to the figures.

[0094] [Figure 1A] FIG. 1A shows a perspective view of the heater assembly. [Figure 1B] FIG. 1B shows a top view of the heater assembly of FIG. 1A. [Figure 1C] FIG. 1C shows a side view of the heater assembly of FIG. 1A. [Figure 2A] FIG. 2A shows a perspective view of another heater assembly. [Figure 2B] FIG. 2B shows a top view of the heater assembly of FIG. 2A. [Figure 3A] FIG. 3A shows a perspective view of a further heater assembly. [Figure 3B] FIG. 3B shows a side view of the heater assembly of FIG. 3A. [Figure 4A] FIG. 4A shows a perspective view of yet a further heater assembly. [Figure 4B] FIG. 4B shows a perspective view of the heater assembly of FIG. 4A, with selected components of the heater assembly shown in transparency. [Figure 5] FIG. 5 shows a schematic cross-sectional view of an aerosol generating device comprising a heater assembly as shown in any of FIGS. 1A-4B. [Figure 6] FIG. 6 shows a schematic cross-sectional view of an aerosol generation system comprising the aerosol generation device shown in FIG. 5 and a cartridge coupled to the aerosol generation device. [Figure 7] FIG. 7 shows a cross-sectional schematic view of a cartridge according to yet another embodiment, the cartridge including the heater assembly shown in any of FIGS. 1A-4B. DETAILED DESCRIPTION OF THE INVENTION

[0095] 1A shows a perspective view of a heater assembly 100. The heater assembly 100 is an aerosol-generating system, such as an electrically operated smoking system, often referred to as an e-cigarette system. The aerosol-generating system may be a handheld, portable system and has a size comparable to a traditional cigar or cigarette.

[0096] The heater assembly 100 includes a frame 120. The frame 120 has a length and a width in a first plane and a height perpendicular to the first plane, the length and width being greater than the height. Thus, the frame 120 has a top surface extending in the first plane. The frame 120 is generally square in shape in the first plane. The corners of the frame 120 in the first plane are radiused. The frame 120 includes an opening 121, which is located in the center of the frame 120. The opening 121 passes through the frame perpendicular to the first plane. The opening 121 is generally square in shape parallel to the first plane. In this embodiment, the opening 121 is the same shape as the frame 120, but this is not necessarily the case. The area of the opening is 100 mm.2 For example, a generally square shaped frame may include a generally circular opening. In the embodiment shown in Figure 1A, the frame is formed from a heat-resistant polymer such as PEEK, although other suitable materials may be used instead.

[0097] The heater assembly 100 further comprises a heating element 130. In the embodiment shown in FIG. 1A, the heating element 130 is parallel to the first plane. The heating element 130 comprises a plurality of heating portions 131 and at least one mounting portion 132. In the embodiment shown in FIG. 1A, the heating element 130 comprises seven heating portions 131 and six mounting portions 132. In the embodiment shown in FIG. 1A, the plurality of heating portions 131 and the at least one mounting portion 132 are integrally formed and comprise stainless steel.

[0098] The heater assembly 100 further includes a first electrical contact 191 and a second electrical contact 192. The first electrical contact 191 is attached to a first end of the heating element 130. The second electrical contact 192 is attached to a second end of the heating element 130. The heating element 130 forms a continuous, serpentine electrical path between the first electrical contact 191 and the second electrical contact 192. This continuous electrical path has a total electrical resistance of approximately 1 ohm. A portion of the heating element 130 overlies the opening 121. In particular, sections of the heating portion 131 and the mounting portion 132 each overlie the opening 121. Portions of the first electrical contact 191 and the second electrical contact 192 protrude from opposite sides of the frame 120 to enable electrical connection to external electronics.

[0099] Mounting portions 132 are each attached to frame 120. In this particular embodiment, frame 120 is overmolded onto the mounting sections of mounting portion 132. First electrical contact 191 and second electrical contact 192 are also attached to frame 120. In this particular embodiment, frame 120 is overmolded onto the mounting sections of first electrical contact 191 and second electrical contact 192. However, overmolding the frame onto the mounting sections may be replaced in alternative embodiments by either snapping, press-fitting, or fastening the two frame elements together.

[0100] The heating element 130 and the first and second electrical contacts 191, 192 are integrally formed and cut from a flat metal sheet, for example by laser cutting, water jet cutting, or chemical etching.

[0101] In this first embodiment, the heating element 130 is uncoated, however, the heating element 130 may be coated with a thin layer of a corrosion-resistant material to extend the life of the heating element 130. An example of such a material is a ceramic material.

[0102] FIG. 1B shows a plan view of the heater assembly 100 according to the embodiment of FIG. 1A. The heating portion 131 is shown having a first width 141 in a first direction, and the mounting portion is shown having a second width 142 also in the first direction. The second width is larger than the first width. The first width is approximately 0.5 millimeters. The second width is approximately 1.5 millimeters. Thus, the ratio of the first width to the second width is approximately 1 / 3. The serpentine shape of the heating element 130 is more clearly seen in this plan view. The heating portion 131 is shown to have a constant width equal to the first width in the first direction along its entire length. The mounting portion 131 is also shown to have a constant width equal to the second width in the first direction along its entire length.

[0103] FIG. 1C shows a side view of the heater assembly 100 according to the embodiment of FIGS. 1A and 1B. The side view is in a first plane. The heating element 130 can be seen to be generally planar in the first plane, in that the heating element 130 extends much further in the first plane than perpendicular to the first plane. The heating element 130 is shown to have a uniform thickness perpendicular to the first plane. The heating element thickness is approximately 0.1 millimeters. Thus, the heating portion 131 and the mounting portion 132 have approximately equal thicknesses perpendicular to the first plane. The heating element 130 is recessed from the top surface 122 of the frame 120 by approximately 2 millimeters. Similarly, the first electrical contact 191 and the second electrical contact 192 are recessed from the top surface 122 of the frame 120 by approximately 2 millimeters. Similarly, the heating element 130 and the first and second electrical contacts are recessed from the underside of the frame 120 .

[0104] The heater assembly 100 is configured to be coupled to the wicking element such that the wicking element is in direct contact with one side of the heating element 130. The other side of the heating element 130 may then be exposed to air.

[0105] When an electric current is passed through the heating element 130 or when a non-zero voltage is applied between the first electrical contact 191 and the second electrical contact 192, the heating element 130 heats up as a result of resistive heating. The electric current passes through the continuous electrical path formed by the heating element 130 in a serpentine direction defined by the shape of the heating element 130. Because the first width is greater than the second width and the heating portions 131 and the mounting portions 132 have approximately equal thicknesses perpendicular to the first plane, the cross-sectional area of each heating portion 131 perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of each mounting portion 132 perpendicular to the direction of the continuous electrical path. Thus, when an electric current is passed through the heating element 130 or when a non-zero voltage is applied between the first electrical contact 191 and the second electrical contact 192, the temperature of the heating portion 131 increases more than the temperature of the mounting portions 132.

[0106] The effect of increasing the temperature of the heating portion 131 more than the temperature of the attachment portion 132 can be achieved in alternative ways. For example, the thicknesses of the heating portion and the attachment portion may be different.

[0107] FIG. 2A shows a perspective view of a heater assembly 200 according to another embodiment. The frame 220 and opening 221 are the same as those shown in FIGS. 1A-1C. The heater assembly 200 includes a heating element 230, which, like the first embodiment, includes multiple heating portions 231 and at least one mounting portion 232. The heater assembly 200 also includes a first electrical contact 291 and a second electrical contact 292, like the first embodiment. This embodiment differs from the embodiment of FIG. 1A in that the heating element 230 further includes at least one thermal insulating portion 235. In the embodiment shown in FIG. 2A, the heating element 230 includes six thermal insulating portions 235. The number of thermal insulating portions 235 is equal to the number of mounting portions 232. Each of the thermal insulating portions 235 is connected between the frame 220 and one of the mounting portions 232. In particular, in the second embodiment, the frame 220 is overmolded onto each section of the thermal insulating portions 235. 2A, the plurality of heating portions 231, the at least one mounting portion 232, and the at least one thermal insulating portion 235 are integrally formed and comprise stainless steel. The plurality of heating portions 231, the at least one mounting portion 232, and the at least one thermal insulating portion 235 have approximately equal thicknesses perpendicular to the first plane.

[0108] FIG. 2B shows a plan view of the heater assembly of FIG. 2A. Similar to the embodiment of FIG. 1A, the heating portion 231 is shown having a first width 241 in a first direction, and the mounting portion is shown having a second width 242 also in the first direction. The second width is larger than the first width. In this second embodiment, the thermal insulation portion 235 has a third width in the first direction. The second width is larger than the third width. The third width is approximately 0.75 millimeters. Thus, the ratio of the third width to the second width is approximately 1 / 2. In the embodiment shown, the third width is larger than the first width, but this is not necessarily the case. For example, the third width may be approximately equal to the first width or may be less than the first width. The thicknesses of the plurality of heating portions 231, at least one mounting portion 232, and at least one thermal insulation portion 235

[0109] When a current passes through heating element 230 or when a non-zero voltage is applied between first electrical contact 291 and second electrical contact 292, heating portion 231 and mounting portion 232 heat up as a result of resistive heating. Although the temperature of mounting portion 232 is lower than the temperature rise of heating portion 231, as described in connection with FIGS. 1A-1C , mounting portion 232 may reach a temperature where direct contact between mounting portion 232 and frame 220 is undesirable. Because the third width of thermally insulating portion 235 is smaller than the second width of mounting portion 232, the amount of energy transferred from the mounting portion to frame 220 when a current passes through heating element 230 is less than if mounting portion 232 were instead attached to frame 220, such as in the first embodiment.

[0110] FIG. 3A shows a perspective view of a heater assembly according to a further embodiment. The frame 320 and opening 321 are identical to those shown in FIGS. 1A-1C and 2A-2B. The heater assembly 300 includes a heating element 330, which includes a plurality of heating portions 331 and at least one mounting portion 332, as in the first and second embodiments. The heater assembly 300 also includes a first electrical contact 391 and a second electrical contact 392, as in the embodiments of FIGS. 1A-C and 2A-2B. This further embodiment differs from the embodiment of FIG. 1A in the shape of the heating element 330, which can also be seen in FIG. 3B.

[0111] 3B shows a side view of a heater assembly according to a further embodiment. Each of the plurality of heating segments 331 has a radius of curvature perpendicular to the first plane. The outer surface of the curved heating segment 331 is configured to be coupled to a wicking element.

[0112] The mounting section of mounting portion 332 and sections of first and second electrical contacts 391, 392 are recessed approximately 2 millimeters from top surface 322 of frame 320. Similarly, the mounting section of mounting portion 332 and sections of first and second electrical contacts 391, 392 are recessed from the bottom surface of frame 320. Mounting portion 332 and first and second electrical contacts 391, 392 include two sets of approximately 90-degree bends. A first set of approximately 90-degree bends 336 orients mounting portion 332 and first and second electrical contacts 391, 392 to extend perpendicular to the first plane. A second set of approximately 90-degree bends 337 orients mounting portion 332 and first and second electrical contacts 391, 392 away from perpendicular to the first plane. Thus, two sets of approximately 90 degree bends are positioned such that a plurality of heating portions 331 intersect the top surface 322 of the frame 320, with at least a portion of each heating portion 331 extending beyond the plane formed by the top surface 322 of the frame 320. In this further embodiment, the heating element is bent by cold stamping or microbending.

[0113] FIG. 4A shows a perspective view of a heater assembly according to yet a further embodiment. The heater assembly 400 includes a heating element 430, which includes a plurality of heating portions 431 and at least one mounting portion 432, as in the previous embodiment. The heater assembly 400 also includes a first electrical contact 491 and a second electrical contact 492, as in the previous embodiment. In contrast to the first embodiment, in this yet further embodiment, the heater assembly 400 further includes a support structure 460. The frame 420 surrounds the support structure 460 in a first plane. The support structure 460 can be considered to be located within an opening in the frame 420. The frame 420 includes a circular perimeter and a generally oval-shaped opening. The support structure 460 includes a generally oval-shaped perimeter that is the same size and shape as the generally oval-shaped opening in the frame, such that a gap between the frame 420 and the support structure 460 is minimized. The support structure 460 includes a generally oval-shaped support structure opening 461 in a first plane. The support structure 460 includes an upper support structure surface 462 that is parallel to the first plane and coplanar with the top surface 422 of the frame 420. The plurality of heating elements 431 are coplanar with the upper support structure surface 462 and above the support structure opening 461.

[0114] FIG. 4B shows a perspective view of the heater assembly of FIG. 4A, with selected components of the heater assembly shown in transparency. In particular, the frame 420 and the support structure 460 are shown in transparency. Each mounting portion 432 includes a first section 433 and a second section 434. Each first section 433 rests on an upper support structure surface 462 and can therefore be considered to be flush with the upper support structure surface 462. Each mounting portion 432 further includes a first set of approximately 90-degree bends 437. The first set of 90-degree bends orient each second section 434 so that the second section 434 extends from the upper support structure surface 462 perpendicular to the upper support structure surface 462. Thus, each second section 434 is positioned between the frame 420 and the support structure 460.

[0115] Additionally, both the first and second electrical contacts 491, 492 include a first electrical contact section 493, a second electrical contact section 494, and a third electrical contact section 495. In a manner similar to that of the mounting portion 432, both first electrical contact sections 493 are substantially flush with the upper support structure surface 462. Both the first and second electrical contacts 491, 492 further include two approximately 90-degree bends 497, 496. The first pair of 90-degree bends 497 orient both second electrical contact sections 494 such that they extend from the upper support structure surface 462 perpendicular to the upper support structure surface 462. Thus, both second electrical contact sections 494 are positioned between the frame 420 and the support structure 460. A second pair of 90 degree bends 498 orients the third electrical contact section 495 so that it is flush with the underside of the frame and parallel to the first plane. In this embodiment, the heating element is bent by cold stamping or microbending.

[0116] FIG. 5 shows a cross-sectional schematic view of an aerosol generating device 510, comprising a heater assembly 500 according to any of the previously described embodiments.

[0117] The aerosol-generating device 510 is an electrically operated smoking device, often referred to as an e-cigarette system. The aerosol-generating device 510 is a handheld, portable device, comparable in size to a traditional cigar or cigarette.

[0118] The device 510 includes a battery 511 , such as a lithium iron phosphate battery, and a controller 512 electrically connected to the battery 511 .

[0119] Device 510 includes an outer casing 517. The outer casing houses a battery 511 and a controller 512. Device 510 is configured to be coupled to a cartridge containing a wicking element and an aerosol-forming substrate. Device 510 includes a cartridge coupling portion 518 extending from a proximal end of device 510. Cartridge coupling portion 518 extends annularly from outer casing 517 and provides a cavity within which the cartridge can be received.

[0120] The heater assembly 500 includes a fluid-permeable heating element 530 and a frame 520, both as described in the previous embodiments. First and second electrical contacts (not shown) are electrically connected to the heating element 530, the battery 511, and the controller 512.

[0121] Device 510 comprises a device air inlet 513 and a device air outlet 514. Device air inlet 513 is defined in a sidewall of device 610. A device air outlet is defined at the proximal end of the device. Device 510 comprises a device airflow passage 519. Device airflow passage 519 is defined between device air inlet 513 and device air outlet 514. Heating element 530 is positioned downstream of device air inlet 513 and upstream of device air outlet 514 and is in fluid communication with device airflow passage 519. In particular, an underside of heating element 530 is in fluid communication with device airflow passage 519. It can be seen that device airflow passage 519 comprises a heater assembly airflow passage. The heater assembly airflow passage is defined between the heater assembly air inlet and the heater assembly air outlet. In the embodiment shown, device air outlet 514 comprises a heater assembly air outlet.

[0122] The apparatus 510 may further include a spring element 516. The spring element 516 is fixed relative to the outer casing 517 and is in contact with the heater assembly 500.

[0123] FIG. 6 shows a schematic cross-sectional view of an aerosol generation system comprising an aerosol generation device as described with reference to FIG. 5 and a cartridge coupled to the aerosol generation device.

[0124] Cartridge 660 is coupled to device 610 by cartridge coupling portion 618. Cartridge 660 comprises a liquid aerosol-forming substrate 662 within reservoir 661 and a ceramic wicking element 669. In this system, reservoir 661 is in fluid communication with ceramic wicking element 669 such that liquid aerosol-forming substrate 662 can flow from reservoir 661 to wicking element 669. Wicking element 669 comprises a capillary material having a fibrous or spongy structure. Wicking element 669 also forms part of the outer surface of cartridge 660.

[0125] The device air outlet 614 is configured to align with the cartridge air inlet 663 when the device 610 is coupled to the cartridge 660. When the device 610 is coupled to the cartridge 660, the device airflow passage 619 is connected to the cartridge airflow passage 668, defining a system airflow passage from the device air inlet 613 to the cartridge air outlet 664. The cartridge includes a mouthpiece 665, and the cartridge air outlet 664 is defined within the mouthpiece 665.

[0126] The wicking element 669 is configured to align with an opening in the frame of the heater assembly. In this particular embodiment, when the system includes a heater assembly according to the first embodiment, the opening is approximately 100 mm. 2 The wicking element 669 also has a generally square cross-section with approximately the same cross-sectional area so that the wicking element 669 can be easily received by an opening in the frame of the heater assembly. When the cartridge 660 is coupled to the device 610, the distal end of the wicking element contacts the upper side of the heating element 630.

[0127] The device 610 may further include a spring element 616. The spring element 616 is fixed relative to the device outer casing 617 and is in contact with the heater assembly 600. When a user couples the cartridge 650 to the device 610, the spring element 617 exerts a force on the heater assembly 600. The force applied to the heater assembly 600 ensures that good contact is made between the top side of the heating element 630 and the wicking element 669.

[0128] During use, a user puffs on the mouthpiece of the cartridge 665, drawing air into the device air inlet 613. The system 650 is puff-activated, meaning that a puff sensor (not shown), which may be a pressure sensor or an airflow sensor, is located within the system 650. In particular, the puff sensor will be in fluid communication with the system airflow path, preferably located within or adjacent to the device airflow path 619. The puff sensor will detect a user puff and send a signal to the controller 612, which will then provide power from the battery 611 to the heating element 630 of the heater assembly via the first and second electrical contacts. This causes current to flow through the heating element 630, thereby resistively heating it. In other embodiments, the aerosol generation system 650 may include a button that the user presses to send a signal to the controller 612 to provide power from the battery 611 to the heating element 630.

[0129] When the heating element 630 is heated, it heats the wicking element 669 and, therefore, the aerosol-forming substrate 662 contained within the wicking element 669. The heating of the wicking element 669 causes the aerosol-forming substrate 662 to vaporize.

[0130] When a user puffs on cartridge air outlet 664, air is drawn into device air inlet 613. As the air is drawn through the air passageway, it passes across the heater assembly. The air flows across the underside of heating element 630, across the surface of wicking element 669, and toward cartridge air outlet 664. Vaporized aerosol-forming substrate 662 is entrained in this flowing air. This entrained vapor then cools and condenses to form an aerosol. The aerosol leaves device airflow passageway 619 through air outlet 614. The aerosol then enters cartridge 660 through cartridge air inlet 663, exits cartridge 660 through cartridge air outlet 664, and is delivered to the user's mouth.

[0131] As the liquid aerosol-forming substrate 662 in the wicking element 669 is heated, vaporized, and entrained in the airflow, the liquid aerosol-forming substrate 662 from the reservoir 661 advances into the wicking element 669. This aerosol-forming substrate 662 from the reservoir 661 effectively replaces the vaporized aerosol-forming substrate 662. Because the wicking element 669 is a capillary material having a fibrous or spongy structure, the liquid aerosol-forming substrate 662 from the reservoir 661 can be drawn into the wicking element 669 at least in part by capillary action.

[0132] After many uses of the aerosol-generating system 650, the wicking element 669 may begin to degrade, or the reservoir 661 may empty the aerosol-forming substrate 662. The user can then uncouple the cartridge 660 from the device 610. The cartridge 660 can be removed and discarded. The aerosol-generating device 610 can then be reused with a new cartridge.

[0133] FIG. 7 shows a cross-sectional schematic view of a cartridge 760 according to another embodiment, the cartridge 760 including a heater assembly 700 according to any of the embodiments described with reference to FIGS. 1A-4B.

[0134] 6, the cartridge 760 shown in FIG. 7 comprises a liquid aerosol-forming substrate 762 within a reservoir 761 and a ceramic wicking element 769. In this system, the reservoir 761 is in fluid communication with the ceramic wicking element 769 such that the liquid aerosol-forming substrate 662 can flow from the reservoir 661 to the wicking element 669. The cartridge further comprises a mouthpiece 765, and a cartridge air outlet 764 is defined within the mouthpiece 765.

[0135] 5 and 6, the heater assembly 700 is located within the cartridge 760 rather than the aerosol generating device. The heater assembly 700 is positioned such that the wicking element 769 is aligned with an opening in the frame of the heater assembly 700 and the distal end of the wicking element 769 contacts the upper side of the heating element 730. Additionally, the cartridge includes a cartridge air inlet 763 upstream of the heater assembly 700 such that a cartridge airflow path 768 is defined between the cartridge air inlet 763 and a cartridge air outlet 764, and the heating element 730 is in fluid communication with the cartridge airflow path 768.

[0136] The cartridge 760 is configured to be coupled to a suitable aerosol generating device, the device including a battery, such as a lithium iron phosphate battery, a controller electrically connected to the battery, first and second device electrical contact portions, and a cartridge coupling portion providing a cavity into which the cartridge 760 can be received.

[0137] The cartridge 760 includes first and second cartridge electrical contact portions (not shown) configured to contact the first and second device electrical contact portions when the cartridge 760 is coupled to an appropriate device so that power can be supplied from the battery to the heating element 730.

[0138] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like should be understood in all instances to be modified 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 a numerical value that is within the typical standard error for the 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. A heater assembly for an aerosol generator, wherein the heater assembly is Heating element, A first electrical contact that electrically contacts the first end of the heating element, and A second electrical contact that electrically contacts the second end of the heating element, wherein the heating element provides a continuous electrical path between the first electrical contact and the second electrical contact, The heating element comprises a plurality of heating portions and at least one mounting portion positioned between the heating portions along the continuous electrical path. A frame having an opening in the first plane, The heating element is fixed to the frame, and each heating portion is located inside or above the opening, and is separated from the frame by at least one mounting portion. The cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of ​​each mounting portion perpendicular to the direction of the continuous electrical path. A heater assembly in which the heating element further comprises at least one thermally insulating portion, each mounting portion is separated from the frame by one thermally insulating portion, and the plurality of heating portions, the at least one mounting portion, and the at least one thermally insulating portion are all integrally formed.

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

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

4. The heater assembly according to claim 3, wherein each thermal insulation portion has a third width in the first direction, and the third width is smaller than the second width.

5. The heater assembly according to claim 1, wherein the heating element is substantially flat.

6. The heater assembly according to claim 1, wherein the frame is overmolded onto the section of the heating element.

7. The heater assembly according to claim 1, wherein the frame comprises an upper element and a lower element.

8. The heater assembly according to claim 1, wherein the frame is electrically insulating.

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

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

11. The heater assembly according to any one of claims 1 to 10, wherein the heating element has a meandering shape.

12. Aerosol generator, It is a heater assembly, and the heater assembly is Heating element, A first electrical contact that electrically contacts the first end of the heating element, and A second electrical contact that electrically contacts the second end of the heating element, wherein the heating element provides a continuous electrical path between the first electrical contact and the second electrical contact, The heating element comprises a plurality of heating portions and at least one mounting portion positioned between the heating portions along the continuous electrical path. A frame having an opening in the first plane, The heating element is fixed to the frame, and each heating portion is located inside or above the opening, and is separated from the frame by at least one mounting portion. The cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of ​​each mounting portion perpendicular to the direction of the continuous electrical path. A heater assembly comprising the heating element further comprising at least one thermal insulation portion, each mounting portion being separated from the frame by one thermal insulation portion, and the plurality of heating portions, the at least one mounting portion, and the at least one thermal insulation portion all integrally formed, An airflow passage defined between an air intake and an air outlet, which is in fluid communication with the heating element, A power supply configured to electrically contact the first and second electrical contacts and supply power to the heating element, An aerosol generator comprising a control circuit configured to control the supply of power from the power source to the heating element.

13. Aerosol generation system, A cartridge, wherein the cartridge is An aerosol-forming substrate that communicates with a wicking material and fluids, The wicking material comprises an aerosol-forming substrate that forms part of the outer surface of the cartridge, an aerosol generator, wherein the aerosol generator is A heater assembly, wherein the heater assembly is Heating element, A first electrical contact that electrically contacts the first end of the heating element, and A second electrical contact that electrically contacts the second end of the heating element, wherein the heating element provides a continuous electrical path between the first electrical contact and the second electrical contact, The heating element comprises a plurality of heating portions and at least one mounting portion positioned between the heating portions along the continuous electrical path. A frame having an opening in the first plane, The heating element is fixed to the frame, and each heating portion is located inside or above the opening and separated from the frame by at least one mounting portion. The cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of ​​each mounting portion perpendicular to the direction of the continuous electrical path. A heater assembly comprising the heating element further comprising at least one thermal insulation portion, each mounting portion being separated from the frame by one thermal insulation portion, and the plurality of heating portions, the at least one mounting portion, and the at least one thermal insulation portion all integrally formed, An airflow passage defined between an air intake and an air outlet, wherein the airflow passage is in fluid communication with the heating element, A power supply configured to electrically contact the first and second electrical contacts and supply power to the heating element, The aerosol generator comprises a control circuit configured to control the power supply from the power source to the heating element, An aerosol generating system in which the cartridge is reversibly connectable to the aerosol generating device such that the wicking material comes into direct contact with the heating element when the cartridge is connected to the aerosol generating device.

14. A cartridge for an aerosol generation system, A wicking material and an aerosol-forming substrate that communicates with fluids, Furthermore A heater assembly, wherein the heater assembly is The wicking material is in contact with the heating element, A first electrical contact that electrically contacts the first end of the heating element, and A second electrical contact that electrically contacts the second end of the heating element, wherein the heating element provides a continuous electrical path between the first electrical contact and the second electrical contact, The heating element comprises a plurality of heating portions and at least one mounting portion positioned between the heating portions along the continuous electrical path. A frame having an opening, The heating element is fixed to the frame, and each heating portion is located inside or above the opening and separated from the frame by at least one mounting portion. The cross-sectional area of ​​each heating portion perpendicular to the direction of the continuous electrical path is smaller than the cross-sectional area of ​​each mounting portion perpendicular to the direction of the continuous electrical path. A cartridge comprising a heater assembly in which the heating element further comprises at least one thermal insulating portion, each mounting portion is separated from the frame by one thermal insulating portion, and the plurality of heating portions, the at least one mounting portion, and the at least one thermal insulating portion are all integrally formed.

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