Cartridge for an aerosol-generating system

Abstract

To provide a cartridge for an aerosol-generating system.SOLUTION: A cartridge (100) comprises a housing (105) having a mouth end opening (110) and an air inlet (150), a storage compartment (135) in the housing and configured to contain a liquid aerosol-forming substrate (131), an airflow passage (140) extending from the air inlet to the mouth end opening, a fluid permeable aerosol-generating element (121) in the housing and having a first surface and a second surface opposite the first surface, the second surface in fluid communication with the storage compartment, and a removable seal (310) having a sealing portion (320) and a tab portion (330) connecting the sealing portion, the sealing portion positioned in the airflow passage outside the first surface of the fluid permeable aerosol-generating element, and the tab portion extending outwardly from the housing through the air inlet.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a cartridge for an aerosol generating system configured to heat a liquid aerosol-forming substrate to generate an aerosol, and in particular to a handheld aerosol generating system, such as an electronically operated smoking system. [Background technology]

[0002] In many handheld aerosol generating systems, an electric heater is used to vaporize a liquid aerosol-forming substrate to generate an aerosol. The liquid substrate is typically contained in a replaceable cartridge having a mouth end through which a user draws the generated aerosol and a connecting end opposite the mouth end. In one embodiment, the electric heater is provided with a fluid-permeable mesh at the connecting end for connection to a control unit containing control circuitry and a power source. The liquid is held in a storage compartment between the heater element and the mouth end of the cartridge. Such a replaceable cartridge allows the user to replace consumed liquid substrate without discarding other components of the system, such as the power source, and allows for simple connection of the heater to a power source. However, during use, due to the orientation of the heater and storage compartment, the liquid substrate may leak through the heater element under the influence of gravity.

[0003] To reduce leakage, cartridges have been developed that include a storage compartment divided into an upper section for storing bulk liquid and a smaller lower section that contains capillary material. The upper and lower sections are connected to allow liquid to pass from the upper section to the lower section, with the heater element located between the two sections and in contact with the capillary material. This allows for gravity-assisted delivery of the liquid substrate from the upper section to the capillary material before being drawn upward by capillary movement to the heater element. This cartridge design ensures that the capillary material is saturated with the liquid substrate, yet reduces leakage issues during use.

[0004] However, due to their complex design, such prior art cartridges are difficult to mass-produce economically by conventional techniques such as injection molding. In addition, it would be desirable to further prevent leakage of liquid from the cartridge during shipping and storage. Summary of the Invention

[0005] In a first aspect of the present invention, there is provided a cartridge for an aerosol generation system, the cartridge comprising: a housing having an opening at a mouth end and an air inlet; a storage compartment within the housing and configured to contain a liquid aerosol-forming substrate; an airflow passage extending from the air inlet to the opening at the mouth end; a fluid-permeable aerosol generation element within the housing and having a first surface and a second surface opposite the first surface, the second surface being in fluid communication with the storage compartment; and a removable seal having a sealing portion and a tab portion connecting the sealing portion, the sealing portion being positioned within the airflow passage outside the first surface of the aerosol generation element, and the tab portion extending outward from the housing through the air inlet.

[0006] The aerosol-generating element may be a heater element. The aerosol-generating element may be a mesh heater. The mesh heater may allow a liquid aerosol-forming substrate stored in the storage compartment to pass through gaps in the mesh heater from its second surface to its first surface. Alternatively, the aerosol-generating element may be a vibrating element.

[0007] The removable seal is positioned outside the first surface of the aerosol-generating element within the airflow passage during shipping and storage of the cartridge. As used herein, storage can refer to long-term storage (e.g., storage at warehouses and points of sale) and storage before first use. The sealing portion functions to block fluid communication between the aerosol-generating element and the airflow passage. This can be achieved by directly sealing the first surface or by sealing off a section of the housing adjacent to the first surface (e.g., the inner wall of the housing). By sealing off fluid communication between the first surface and the airflow passage, leakage and evaporation of the liquid aerosol-forming substrate can be eliminated or at least reduced during shipping and storage.

[0008] The tab portion forms a portion of the removable seal that is accessible by the user, i.e., when the sealing portion of the removable seal is positioned outside the first surface within the airflow passage, the tab portion extends beyond the exterior surface of the housing.

[0009] Pulling the seal portion through the air inlet allows for the use of a shorter removable seal.

[0010] Optionally, when positioned within the airflow passage, the sealing portion forms an airtight seal within the airflow passage. For example, the sealing portion may extend across the airflow passage to form an airtight closure to prevent airflow through the airflow passage. This prevents dust and dirt from accumulating within the airflow passage. Optionally, the sealing portion extends from the opening at the mouth end to the air inlet. Optionally, the sealing portion is configured to match the dimensions of the airflow passage, thereby completely closing off the airflow passage.

[0011] Optionally, applying a pulling force to the tab portion removes the seal portion from the exterior of the first surface, thereby placing the first surface in fluid communication with the airflow passage. Prior to first use, a user pulls the tab portion of the removable seal from the cartridge, thereby withdrawing the removable seal from the airflow passage. Removal of the removable seal establishes fluid communication between the aerosol generation element and the airflow passage. This allows the generated aerosol to be inhaled by the user through the opening in the mouth end. The surface of the tab portion may have indentations and / or protrusions to improve a user's grip on the tab portion. Advantageously, the surface area of ​​the tab portion is large enough to be easily grasped by a user's fingers.

[0012] Optionally, the removable seal is reusable. The removed seal portion may be reinserted into the airflow passage so that it is positioned within the airflow passage outside the first surface of the aerosol-generating element. This allows the cartridge to be resealed for further storage and transport following the first use.

[0013] Optionally, the removable seal comprises a retaining means for retaining the removable seal on the outside of the first surface of the aerosol generating element until the pulling force is applied on the tab portion. The retaining means may be any retaining means known to those skilled in the art, for example, the retaining means may be a mechanical retaining means such as a spring clip or a latch that engages with the first surface and / or housing, or the retaining means may be achieved by a bonding technique such as adhesive sealing, heat sealing, or induction heating sealing.

[0014] Optionally, a tab portion extends outwardly from the housing through the opening in the mouth end, which allows the opening in the mouth end to be closed by the tab portion and may serve as a reminder to the user to remove the removable seal before operation.

[0015] Optionally, a safety mechanism is provided to prevent activation of the aerosol-generating element before the sealing portion is removed from the airflow passage. Such a safety mechanism may be any mechanism known to those skilled in the art, such as a removable connector seal and an interlock integrally formed with the sealing portion, or the safety mechanism may be a more complex electronic sensor, such as an airflow sensor or pressure-activated switch, in communication with the airflow passage. The safety mechanism serves the purpose of preventing unintentional heater activation, while the sealing portion is located outside the heater element.

[0016] Optionally, the removable seal may be made from thermoplastic elastomer (TPE), styrene ethylene butylene styrene (SEBS), polyethersulfone (PESU), rubber, silicone, or any other suitable material known to those skilled in the art. The tab portion and seal portion may be molded or extruded from a single piece of material, or may be made from different materials for different purposes. For example, the seal portion may be made from a more stretchable material than the tab portion to achieve a better seal, while the tab portion may be made from a more resilient material to withstand the pulling force applied by a user during removal of the removable seal.

[0017] Optionally, the tab portion is flexible and configured to bend at the air inlet so as to conform to the exterior profile of the housing. Alternatively, the tab portion may be hingedly connected to the seal portion at the air inlet so that the tab portion conforms to the exterior profile of the housing. More specifically, the tab portion may be arranged to fold at the air inlet during storage and transport so that it extends along the longitudinal axis of the housing. In other words, the tab portion can be tucked away prior to use. In this manner, the tab portion creates minimal protrusion, and the cartridge can be packed into more compact packaging. To remove the removable seal, a user may straighten the tab portion so that it is no longer parallel to the housing before applying a lateral pulling force to remove the removable seal from the housing.

[0018] Optionally, a sealing portion is disposed to provide an airtight seal between the aerosol-generating element and the airflow passage, which not only inhibits the ingress of moisture into the storage compartment, which may affect the quality and stability of the liquid substrate, but also prevents evaporation and / or loss of the liquid substrate from the storage compartment to the atmosphere through the airflow passage.

[0019] Optionally, the storage compartment comprises a first compartment and a second compartment interconnected by a connector, whereby liquid in the first compartment can pass to the second compartment through a liquid passage in the connector, and a first surface of the fluid-permeable aerosol-generating element faces the first compartment and a second surface faces the second compartment, the second surface being in fluid communication with the second compartment, whereby liquid aerosol-forming substrate in the first compartment can reach the fluid-permeable aerosol-generating element only through the second compartment.

[0020] The connector sealingly connects the two separate compartments and provides one or more liquid passageways therebetween. More specifically, the connector separates both the first and second compartments. The connector may be connected to the first and / or second compartments by an interference fit, which reversibly deforms to provide a seal at the connection. This allows for inexpensive mass production of separate components by extrusion or molding before being assembled to form more complex cartridge designs. For example, this allows for the aerosol generation element to be molded with the second compartment before being assembled onto the first compartment via the aforementioned connector. The interference fit can be any suitable interference fit known to those skilled in the art; for example, the interference fit may be an interlocking fit or a snap fit.

[0021] Optionally, the connector and the first surface of the fluid-permeable aerosol generating element define at least a portion of the airflow passage. The connector may define a wall of the airflow passage facing the fluid-permeable aerosol generating element. More specifically, the connector allows the sealing portion of the removable seal to be positioned outside the first surface of the aerosol generating element within the airflow passage prior to assembly of the cartridge. This improves access to the first surface, as the first surface is fully exposed when the sealing portion is in place.

[0022] Optionally, an airflow passage extends from the air inlet to the opening at the mouth end and between the first and second compartments, i.e., the connector not only provides a liquid passage for the aerosol-generating substrate, but also defines a portion of the airflow passage, thereby directing airflow outside the heater element and towards the opening at the mouth end.

[0023] Optionally, an airflow passage may extend through the first compartment. For example, the first compartment may have an annular cross-section, with an airflow passage extending through the first compartment from the aerosol-generating element to the opening at the mouth end. Optionally, the airflow passage may extend from the aerosol-generating element to the opening at the mouth end adjacent the first compartment.

[0024] Optionally, the connector may be manufactured from polypropylene (PP), high density polyethylene (HDPE), copolyester, thermoplastic elastomer (TPE), polysulfone (PSU) styrene ethylene butylene styrene (SEBS), polyethersulfone (PESU), rubber, silicone, or any suitable material known to those skilled in the art. Optionally, the connector may be made from a material capable of maintaining its mechanical integrity at temperatures up to 90° C. Optionally, the connector may be made from a material capable of maintaining its mechanical integrity at temperatures up to 120° C.

[0025] Optionally, the first compartment has a larger liquid storage capacity than the second compartment. Optionally, the first compartment is larger than the second compartment. In use, the first compartment is typically positioned above the aerosol-generating element. Optionally, the first compartment is positioned between the fluid-permeable aerosol-generating element and the opening at the mouth end.

[0026] Optionally, the second compartment contains a capillary material in contact with the second surface of the aerosol-generating element. The capillary material delivers the liquid aerosol-forming substrate to the aerosol-generating element against gravity. By requiring the liquid aerosol-forming substrate to move against gravity to reach the aerosol-generating element, leakage of the liquid substrate is reduced.

[0027] The capillary material may be made of a material capable of ensuring that the liquid aerosol-forming substrate is in contact with at least a portion of the second surface of the aerosol-generating element. The capillary material may extend into a gap or opening in the aerosol-generating element. The aerosol-generating element may draw the liquid aerosol-forming substrate into the gap or opening by capillary action.

[0028] A capillary material is a material that actively transports liquid from one end of the material to another. The capillary material may have a fibrous or spongy structure. Preferably, the capillary material comprises a bundle of capillaries. For example, the capillary material may comprise a plurality of fibers or threads or other fine tubes. The fibers or threads may be generally aligned to transport the liquid aerosol-forming substrate toward the aerosol-generating element. Alternatively, the capillary material may comprise a spongy or foam-like material. The structure of the capillary material forms a plurality of small holes or tubes through which the liquid aerosol-forming substrate can be transported by capillary action. The capillary material may comprise any suitable material or combination of materials. Examples of suitable materials are sponge or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, expanded metal or plastic materials, fibrous materials (e.g., made from spun or extruded fibers (cellulose acetate, polyester, or bonded polyolefins), polyethylene, ethylene, or polypropylene fibers, nylon fibers, or ceramics). Capillary materials may have any suitable capillary action and porosity, allowing for the use of different liquid physical properties. Liquid aerosol-forming substrates have physical properties, including, but not limited to, viscosity, surface tension, density, thermal conductivity, boiling point, and vapor pressure, that allow the liquid aerosol-forming substrate to be transported through the capillary medium by capillary action.

[0029] Alternatively, or in addition, the storage compartment may contain a carrier material for holding the liquid aerosol-forming substrate. The carrier material may be in the first compartment, the second compartment, or both the first and second compartments. The carrier material may be a spongy mass of foam and fiber collection. The carrier material may be formed of a polymer or copolymer. In one embodiment, the carrier material is a spun polymer. The aerosol-forming substrate may be released into the carrier material during use. For example, the liquid aerosol-forming substrate may be provided in a capsule.

[0030] Optionally, the cartridge includes a heater assembly, the heater assembly including a heater element electrically connected to the heater element and an electrical contact portion exposed through the connecting end of the cartridge, thereby enabling contact with an electrical contact pin in a control body of the aerosol generation system. The connecting end is remote from the mouth end characterized by an opening in the mouth end. The connecting end is configured to connect to a control body of the aerosol generation system. A second side of the aerosol generation element may face the connecting end, and a first side of the aerosol generation element may face the mouth end. Power may be delivered to the aerosol generation element from the connected control body through the connecting end of the housing.

[0031] Optionally, the electrical contact portions are two conductive contact pads. The conductive contact pads may be located in the edge region of the heater element. Optionally, at least two conductive contact pads may be located on the tip of the heater element. The conductive contact pads may be fixed directly to the conductive filament of the heater element. The conductive contact pads may comprise tin patches. Alternatively, the conductive contact pads may be integral with the heater element.

[0032] Optionally, the aerosol generation element is closer to the connection end than to the opening in the mouth end, which allows for a simple and short electrical connection path between the power source in the control body and the aerosol generation element.

[0033] Optionally, the storage compartment may include a heater mount, which is molded to the exterior of the heater assembly.

[0034] Optionally, the first and second surfaces of the aerosol generating element may be substantially planar. The aerosol generating element may be a heater element. The heater element may comprise a substantially flat heater element to allow for simple manufacturing. Geometrically, the term "substantially flat" heater element is used to refer to a heater element that is substantially in the form of a two-dimensional plane. A substantially flat heater element therefore extends in two dimensions along a surface rather than in three dimensions. In particular, the dimension of a substantially flat heater element in two dimensions within its surface is at least five times greater than the dimension in three dimensions perpendicular to the surface. An example of a substantially flat heater element is a structure between two substantially parallel imaginary surfaces, where the distance between these two imaginary surfaces is substantially less than the extension within the surfaces. In some embodiments, the substantially flat heater element is planar. In other embodiments, the substantially flat heater element is curved along one or more dimensions, for example, forming a dome or bridge shape.

[0035] The heater element may include a plurality of gaps or openings extending from the second surface to the first surface and through which a fluid may pass.

[0036] The heater element may comprise multiple conductive filaments. The term "filament" is used throughout this specification to refer to an electrical path disposed between two electrical contacts. The filament may arbitrarily branch and diverge into several paths or filaments, respectively, or several electrical paths may merge into one path. The filaments may have a cross section that is round, square, flat, or of any other shape. The filaments may be arranged in a straight or curved manner.

[0037] The heater element may be, for example, an array of filaments arranged parallel to one another. Preferably, the filaments may form a mesh. The mesh may be woven or non-woven. The mesh may be formed using different types of weave or lattice structures. Alternatively, the conductive heater element may consist of an array of filaments or a woven fabric of filaments. A mesh, array, or woven fabric of conductive filaments may also be characterized by its ability to retain liquid.

[0038] In a preferred embodiment, the substantially flat heater element may be constructed of wires formed into a wire mesh. The mesh preferably has a plain weave design. Optionally, the heater element is a wire grill made from mesh strips.

[0039] The conductive filaments may define gaps between the filaments, and the gaps may have a width of 10 micrometers to 100 micrometers. The filaments preferably create capillary action within the gaps so that liquid to be vaporized in use is drawn into the gaps, increasing the contact area between the heater element and the liquid aerosol-forming substrate.

[0040] The conductive filaments may form a mesh having a size of 60 to 240 filaments per centimeter (±10 percent). The mesh density is preferably 100 to 140 filaments per centimeter (±10 percent). The mesh density is more preferably approximately 115 filaments per centimeter. The gap width may be 100 micrometers to 25 micrometers, preferably 80 micrometers to 70 micrometers, and more preferably approximately 74 micrometers. The open area of ​​the mesh, which is the ratio of the gap area to the total area of ​​the mesh, may be 40 percent to 90 percent, preferably 85 percent to 80 percent, and more preferably approximately 82 percent.

[0041] The conductive filaments may have a diameter of 8 micrometers to 100 micrometers, preferably 10 micrometers to 50 micrometers, more preferably 12 micrometers to 25 micrometers, and most preferably approximately 16 micrometers. The filaments may have a round or flattened cross section.

[0042] The area of ​​the conductive filament mesh, array, or woven fabric may be small, for example, 50 square millimeters or less, preferably 25 square millimeters or less, and more preferably approximately 15 square millimeters. The size is selected to allow the heater element to be incorporated into a handheld system. Sizing the conductive filament mesh, array, or woven fabric to 50 square millimeters or less reduces the total amount of power required to heat the conductive filament mesh, array, or woven fabric while still ensuring sufficient contact of the conductive filament mesh, array, or woven fabric with the liquid aerosol-forming substrate. The conductive filament mesh, array, or woven fabric may be rectangular, for example, and may have a length of 2 to 10 millimeters and a width of 2 to 10 millimeters. The mesh preferably has dimensions of approximately 5 millimeters by 3 millimeters.

[0043] The heater element filaments may be formed of any material having suitable electrical properties. Suitable materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. An example of a suitable doped ceramic is doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals.

[0044] Examples of suitable alloys include stainless steel, constantan, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation. The filament may be coated with one or more insulators. Preferred materials for the conductive filament are stainless steel and graphite, with 300 series stainless steels, such as AISI 304, 316, 304L, and 316L, being more preferred. Additionally, the conductive heater element may include a combination of the above materials. Combinations of materials may be used to improve resistance control of the substantially planar heater element. For example, a material with a high resistivity may be combined with a material with a low resistivity. This may be advantageous if one of the materials is more advantageous from other perspectives, such as price, machinability, or other physical and chemical parameters. Advantageously, a substantially flat filament arrangement with increased resistance reduces parasitic losses. Advantageously, a heater with high resistance allows for more efficient use of battery energy.

[0045] Optionally, the filament is made of wire. Optionally, the wire is made of metal, most preferably stainless steel.

[0046] The electrical resistance of the mesh, array, or weave of conductive filaments of the heater element can be between 0.3 ohms and 4 ohms. Optionally, the electrical resistance is 0.5 ohms or greater. More preferably, the electrical resistance of the mesh, array, or weave of conductive filaments is between 0.6 ohms and 0.8 ohms, and most preferably about 0.68 ohms. The electrical resistance of the mesh, array, or weave of conductive filaments is preferably at least one order of magnitude greater, and more preferably at least two orders of magnitude greater, than the electrical resistance of the conductive contact area. This ensures that heat generated by passing current through the heater element is localized to the mesh or array of conductive filaments. When the system is battery-powered, a low overall resistance to the heater element is advantageous. A low-resistance, high-current system allows for the delivery of high power to the heater element, allowing the heater element to quickly heat the conductive filaments to the desired temperature.

[0047] Alternatively, the heater element may comprise a heating plate having an array of apertures formed therein. The apertures may be formed, for example, by etching or machining. The plate may be formed from any material having suitable electrical properties, such as the materials described above for the heater element filaments.

[0048] The first surface of the aerosol-generating element may face directly toward the opening in the mouth end. This orientation of the planar aerosol-generating element allows for simple assembly of the cartridge during manufacture.

[0049] The storage compartment may comprise a storage compartment housing. The storage compartment housing may comprise a heater mount, the heater mount being externally molded to the heater assembly. The heater mount may cover a portion of a first surface of the heater assembly to separate the electrical contact portion from the airflow passage, and may cover at least a portion of a second surface of the heater assembly to separate the electrical contact portion from the liquid aerosol-forming substrate.

[0050] The heater mount may include at least one wall extending from the second surface of the heater assembly, the at least one wall forming a portion of the second compartment. The heater mount may define a liquid flow path from the first surface of the heater assembly to the second surface of the heater assembly.

[0051] The liquid storage compartment may hold a liquid aerosol-forming substrate. As used herein with respect to the present invention, an aerosol-forming substrate is a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate. The volatile compound may be released by moving the aerosol-forming substrate through the passage of a vibratable element.

[0052] The aerosol-forming substrate may be liquid at room temperature. The aerosol-forming substrate may contain both liquid and solid components. The liquid aerosol-forming substrate may contain nicotine. The liquid aerosol-forming substrate containing nicotine may be a nicotine salt matrix. The liquid aerosol-forming substrate may contain plant-derived material. The liquid aerosol-forming substrate may contain tobacco. The liquid aerosol-forming substrate may contain tobacco-containing material containing volatile tobacco flavour compounds that are released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may contain homogenised tobacco material. The liquid aerosol-forming substrate may contain non-tobacco-containing material. The liquid aerosol-forming substrate may contain homogenised plant-derived material.

[0053] The liquid aerosol-forming substrate may include one or more aerosol formers. The aerosol former is any suitable, well-known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the system. 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 (such as triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). The liquid aerosol-forming substrate may include water, solvents, ethanol, plant extracts, and natural or artificial flavors.

[0054] The liquid aerosol-forming substrate may comprise nicotine and at least one aerosol former. The aerosol former may be glycerin or propylene glycol. The aerosol former may comprise both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of about 0.5% to about 10% (e.g., about 2%).

[0055] The housing may be formed from a moldable plastic material such as polypropylene (PP) or polyethylene terephthalate (PET). The housing may form some or all of the walls of the storage compartment. The housing and storage compartment may be integrally formed. Alternatively, the storage compartment may be formed separately from the housing and assembled to the housing.

[0056] The cartridge may include a removable mouthpiece through which the aerosol can be drawn by a user. The removable mouthpiece may cover the opening in the oral end. Alternatively, the cartridge may be configured to allow a user to breathe directly on the opening in the oral end.

[0057] The cartridge may be refillable with liquid aerosol-forming substrate, or alternatively, the cartridge may be designed to be discarded when the storage compartment is emptied of liquid aerosol-forming substrate.

[0058] In a second aspect of the present invention, there is provided a cartridge for an aerosol generation system, the cartridge comprising:

[0059] a housing having an opening at a mouth end and an air inlet; a storage compartment within the housing configured to contain a liquid aerosol-forming substrate, the storage compartment having a first compartment and a second compartment connected to one another by a connector such that liquid in the first compartment can pass to the second compartment through a liquid passage in said connector; an airflow passageway extending from the air inlet to the opening at the mouth end, the airflow passageway passing between the first compartment and the second compartment of the storage compartment; a fluid-permeable aerosol-generating element having a first surface and a second surface opposite the first surface, the first surface of the fluid-permeable aerosol-generating element facing the first compartment and the second surface facing the second compartment, the second surface being in fluid communication with the second compartment, such that liquid aerosol-forming substrate in the first compartment can only reach the fluid-permeable aerosol-generating element through the second compartment, and the first surface and the connector forming part of an airflow passage; The liquid aerosol-forming substrate in the first compartment can only reach the fluid-permeable aerosol-generating element through the connector and the second compartment.

[0060] The features of the cartridge of the first aspect of the invention may be applied to the second aspect of the invention.

[0061] In a third aspect of the present invention, there is provided an aerosol generation system comprising a cartridge according to any one of the first or second aspects and a control body connected to the cartridge, the control body being configured to control the supply of power to the aerosol generation element.

[0062] The control body may include at least one electrical contact element configured to provide an electrical connection to the aerosol generation element when the control body is connected to the cartridge. The electrical contact element may be elongated. The electrical contact element may be spring-loaded. The electrical contact element may contact an electrical contact pad within the cartridge.

[0063] The control body may include a connecting portion for engaging a connecting end of the cartridge.

[0064] The control body may include a power source.

[0065] The control body may comprise a control circuit configured to control the supply of power from the power source to the aerosol generation element.

[0066] The control circuit may comprise a microcontroller. Preferably, the microcontroller is a programmable microcontroller. The control circuit may comprise further electronic components. The control circuit may be configured to regulate the power supply to the aerosol generation element. Power may be supplied to the aerosol generation element continuously after activation of the system, or may be supplied intermittently, such as with each puff. Power may be supplied to the aerosol generation element in the form of current pulses.

[0067] The control body may comprise a power supply arranged to provide power to at least one of the control system and the aerosol generation element. The aerosol generation element may comprise an independent power supply. The aerosol generation system may comprise a first power supply arranged to provide power to the control circuitry and a second power supply configured to provide power to the aerosol generation element.

[0068] The power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a lithium polymer battery. The battery may be a nickel-metal hydride battery or a nickel-cadmium battery. The power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may be configured for numerous charge-discharge cycles. The power source may have a capacity that allows for storage of sufficient energy for one or more user experiences; for example, the power source may have a capacity sufficient to allow continuous generation of aerosol for a period of approximately six minutes, corresponding to the typical time it takes to smoke a conventional cigarette, or a multiple of six minutes. In another embodiment, the power source may have a capacity sufficient to allow for a predetermined number of puffs or for discontinuous activation of the atomization assembly.

[0069] The aerosol generation system may be a handheld aerosol generation system configured to allow a user to draw on the mouthpiece to draw aerosol through an opening in the mouth end. The aerosol generation system may have a size comparable to a conventional cigar or cigarette. The aerosol generation system may have an overall length of about 30 mm to about 150 mm. The aerosol generation system may have an outer diameter of about 5 mm to about 30 mm.

[0070] The cartridge or aerosol generation system of any of the aspects of the invention may include a puff detector in communication with the control circuit, which may be configured to detect when a user inhales through the airflow passage.

[0071] The cartridge or aerosol generation system in any of the embodiments of the present invention may include a temperature sensor in communication with the control circuitry. The cartridge or aerosol generation system may include a user input, such as a switch or button. The user input may allow the user to turn the system on and off.

[0072] The cartridge or aerosol generating system may also comprise an indicator means for indicating to a user the determined amount of liquid aerosol-forming substrate held in the liquid reservoir, and the control circuitry may be configured to activate the indicator means after a determination has been made of the amount of liquid aerosol-forming substrate held in the liquid reservoir.

[0073] The indication means may comprise one or more of a light, such as a light emitting diode (LED), a display, such as an LCD display, an audible indication means, such as a loudspeaker or buzzer, and a vibration means. The control circuit may be configured to illuminate one or more of the lights, indicate the quantity on the display, emit a sound via the loudspeaker or buzzer, and vibrate the vibration means.

[0074] In a fourth aspect of the present invention, there is provided a method for producing a suction cup, comprising: a housing having an opening at a mouth end and an air inlet; a storage compartment within the housing and configured to contain a liquid aerosol-forming substrate; an airflow passage extending from the air inlet to an opening at the mouth end; a fluid-permeable aerosol generation element within the housing and having a first surface and a second surface opposite the first surface, the second surface in fluid communication with the storage compartment; a removable seal having a sealing portion and a tab portion connected to the sealing portion, the sealing portion being positioned in the airflow passage outside the first surface of the aerosol generating element, and the tab portion extending outward from the housing through the air inlet; a control body configured to control the supply of power to the aerosol generating element.

[0075] Features of one aspect of the invention may also be applied to other aspects of the invention.

[0076] Embodiments of the invention will now be described in detail, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0077] [Figure 1a] FIG. 1a is a schematic diagram of an aerosol generation system according to an embodiment of the present invention. [Figure 1b] FIG. 1b is a schematic diagram of a first cross section of the cartridge shown in FIG. 1a. [Figure 1c] FIG. 1c is a schematic diagram of a second cross section of the cartridge shown in FIG. 1a. [Figure 2] Figures 2a and 2b illustrate the fitting of a removable seal to the cartridge of Figures 1a-1c, and Figure 2c illustrates the removal of the removable seal illustrated in Figures 2a and 2b. [Figure 3] FIG. 3 shows a cross-sectional view of a cartridge according to another embodiment of the present invention. [Figure 4a] FIG. 4a is a perspective view of a heater assembly for the cartridge shown in FIG. [Figure 4b] FIG. 4b is a perspective view of a heater assembly for the cartridge shown in FIG. [Figure 5a] FIG. 5a is a perspective view of the cartridge shown in FIG. [Figure 5b] FIG. 5b is an exploded view of the cartridge shown in FIG. 5a. [Figure 6] FIG. 6 is an exploded view of a cartridge according to yet another embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0078] 1 is a schematic diagram of an aerosol generation system. The aerosol generation system comprises two main components: a cartridge 100 and a control body 200. A connecting end 115 of the cartridge 100 is removably connected to a corresponding connecting end 205 of the control body 200. The control body 200 houses a battery 210 (in this example, a rechargeable lithium-ion battery) and a control circuit 220. The aerosol generation device is portable and has a size comparable to that of a conventional cigar or cigarette.

[0079] The cartridge 100 comprises a housing 105 that houses an atomization assembly 120 and a liquid storage compartment having a first portion / compartment 130 and a second portion / compartment 135. A liquid aerosol-forming substrate is held within the liquid storage compartment. As seen in FIG. 1b, the first portion 130 of the liquid storage compartment is connected to the second portion 135 of the liquid storage compartment, thereby allowing liquid in the first portion 130 to pass to the second portion 135. The atomization assembly 120 receives liquid from the second portion 135 of the liquid storage compartment. In this embodiment, the atomization assembly 120 is a generally planar, fluid-permeable heater assembly.

[0080] Airflow passages 140 , 145 extend through the cartridge 100 from the air inlet 150 past the nebulizing assembly 120 and from the nebulizing assembly 120 to the mouth-end opening 110 in the cartridge housing 105 .

[0081] The components of the cartridge 100 are arranged so that the first portion 130 of the liquid storage compartment is between the nebulization assembly 120 and the mouth-end opening 110, and the second portion 135 of the liquid storage compartment is positioned opposite the mouth-end opening 110 of the nebulization assembly 120. In other words, the nebulization assembly 120 is between the two portions 130, 135 of the liquid storage compartment and receives liquid from the second portion 135, and the first portion 130 of the liquid storage compartment is closer to the mouth-end opening 110 than the second portion 135 of the liquid storage compartment. An airflow passage extends past the nebulization assembly 120 and between the first portion 130 and the second portion 135 of the liquid storage compartment.

[0082] The system is configured to allow a user to inhale or draw on the mouth-end opening 110 of the cartridge 100 to thereby draw aerosol into their mouth. In operation, when a user inhales on the mouth-end opening 110, air is drawn from the air inlet 150 through the airflow passageway, past the atomization assembly 120, and into the mouth-end opening 110. A control circuit 220 controls the supply of power from the battery 210 to the cartridge 100 when the system is activated. As a result, the amount and characteristics of the vapor produced by the atomization assembly 120 are controlled. The control circuit 220 may include an airflow sensor, and may provide power to the atomization assembly 120 when the airflow sensor detects a user drawing on the cartridge 100. This type of control arrangement is well established in aerosol-generating systems such as inhalers and e-cigarettes. Thus, when a user draws on mouth-end opening 110 of cartridge 100, nebulization assembly 120 is activated and generates a vapor that is entrained in the airflow passing through airflow passage 140. The vapor cools in the airflow within passage 145 to form an aerosol, which is then drawn through mouth-end opening 110 into the user's mouth.

[0083] In operation, the mouth end opening 110 is typically the highest point of the device. The construction of the cartridge 100, and in particular the arrangement of the nebulization assembly 120 between the first portion 130 and the second portion 135 of the liquid storage compartment, is advantageous because it utilizes gravity to ensure that liquid substrate is delivered to the nebulization assembly 120 even when the liquid storage compartment begins to empty, yet prevents oversupply of liquid to the nebulization assembly 120, which may lead to leakage of liquid into the airflow passage 140.

[0084] Figure 1b is a first cross section of a cartridge 100 for use in the system of Figure 1a. Figure 1c is a second cross section perpendicular to the cross section of Figure 1b.

[0085] The cartridge 100 of FIGS. 1b and 1c includes an outer housing 105 having a mouth end with a mouth-end opening 110 and a connecting end opposite the mouth end. Within the housing 105 is a liquid storage compartment that holds a liquid aerosol-forming substrate 131. Liquid is contained within the liquid storage compartment by three components: an upper storage compartment housing 137, a heater mount 134, and an end cap 138. A heater assembly 120 is held within the heater mount 134. A capillary material 136 is provided within a second portion 135 of the liquid storage compartment and abuts a heater element within a central region of the heater assembly 120. The capillary material is oriented to transport liquid to the heater element. The heater element 121 includes a mesh heater element formed of multiple filaments. Details of this type of heater element structure can be found, for example, in International Patent Publication No. 2015 / 117702. An airflow passage 140 extends between the first and second portions 130, 135 of the liquid storage compartment. The bottom wall of the airflow passage 140 comprises the heater element 121 and heater mount 134, the side walls of the airflow passage 140 comprise portions of the heater mount 134, and the top wall of the airflow passage 140 comprises a portion of the upper storage compartment housing 137. The airflow passage 130 has a vertical portion 145 that extends through the first portion 130 of the liquid storage compartment toward the mouth end opening 110, as shown in FIG. 1b.

[0086] The heater assembly 120 is generally planar and has two sides. The first side of the heater assembly 120 faces the first portion 130 of the liquid storage compartment and the opening 110 at the mouth end. The second side of the heater assembly 120 contacts the capillary material 136 and the liquid 131 within the liquid storage compartment and faces the connecting end 115 of the cartridge 100. The heater assembly 120 is closer to the connecting end so that electrical connection of the heater assembly 120 to a power source can be achieved simply and robustly, as will be described. The first portion 130 of the liquid storage compartment is larger than the second portion 135 of the liquid storage compartment and occupies the space between the heater assembly 120 and the opening 110 at the mouth end of the cartridge 100. Liquid in the first portion 130 of the liquid storage compartment can travel to the second portion 135 of the liquid storage compartment through liquid channels 133 on either side of the heater assembly 120. Although two channels are provided in this embodiment to provide a symmetrical structure, only one channel is necessary. The channel is an enclosed liquid flow path defined between the upper storage compartment housing 137 and the heater mount 134 .

[0087] 2a, 2b, and 2c illustrate an embodiment of the present invention in relation to the cartridge shown in FIGS. 1a-1c. In FIG. 2a, the heater assembly 120 is shown assembled onto the first portion 130 of the storage compartment, with the sealing portion 320 of the removable seal 310 positioned outside the heater element 121, thereby sealing off the first side of the heater element 121 exposed to the airflow passage 140. FIGS. 2b and 2c show the assembled heater assembly 120 with the first portion 130 of the storage compartment and the completed cartridge, respectively. The tab portion 330 of the removable seal 310 is shown extending outward from the airflow passage and protruding from the exterior surface of the housing 105. The tab portion 330 allows a user to remove the sealing portion 320 of the removable seal 310 from the airflow passage 140 by pulling the tab portion 330, thereby establishing fluid communication between the heater element and the airflow passage 140.

[0088] 3 is a cross-section of another embodiment of the present invention. In this embodiment, a seal joint 410 is provided between the first portion 130 of the storage compartment and the heater assembly 120, which is molded with the second portion 135 of the storage compartment. Not only does the seal joint 410 simplify the manufacturing process, as it can be separately manufactured before the second portion 135 and the first portion 130 of the storage compartment are sealingly attached to one another to establish the liquid channel 133, but the seal joint 410 also defines a portion of the airflow passage 140, thereby allowing the seal portion 320 of the removable seal 310 to more easily attach to the heater element 121. The seal joint 410 can also be shaped to direct airflow outside the heater element 121, for example, to create turbulence on the outside surface of the heater element 121 to improve evaporation.

[0089] 4a and 4b are external and cross-sectional perspective views of the heater assembly 120 connected to a seal interface 410. The seal interface 410 forms part of the airflow passage 140, which extends from the air inlet end 440 toward the cartridge end 420. The cartridge end 420 is configured to sealingly cooperate with a corresponding connection in the housing 105, thereby completing the airflow passage 140. As shown in FIGS. 4a and 4b, the connection between the seal interface 140 and the housing 105, as well as the connection between the seal interface 410 and the heater assembly 120, are both achieved by an interference fit to provide a sealed connection. The interference fit, shown in FIG. 4b as a pair of ribs projecting from and along the periphery of the exterior surface of the seal interface 410, is compressed when the seal interface is mated with the housing 105 to provide a seal at the connection. Similar ribs (not shown) protrude from and along the periphery of the inner surface of seal joint 410 and are arranged to form a seal at the connection with heater assembly 120. The ribs 450 in the illustrated embodiment are integrally formed with seal joint 410, with both the ribs and seal joint 410 being made from the same material. However, the ribs 450 could be replaced by elastomeric O-rings or any other material different from that of seal joint 410.

[0090] In the particular embodiment shown in FIG. 4b, the seal portion 320 of the removable seal 310 engages with the heater assembly 120 via a mechanical seal 340. That is, a ring of protrusions on the mechanical seal 340 engages with a corresponding grooved ring on the heater assembly 120, thus locking the seal portion 320 in place. The mechanical seal 340 is made of a resilient material, and its attachment to the grooved ring creates an airtight seal between the heater element 121 and the airflow passage 140. The use of such a mechanical seal 340 not only prevents leakage of the liquid substrate during shipping and storage, but also prevents evaporation of the liquid substrate from the second portion 135 of the storage compartment. The mechanical seal 340 is configured to disengage from the heater assembly upon application of a pulling force to the tab portion 330.

[0091] When positioned within the airflow passage 140, the sealing portion 320 not only covers and seals the first side of the heater element 121 from the airflow passage, but also blocks the airflow passage 140, thereby preventing dust and dirt from accumulating therein.

[0092] The seal joint 410 also includes a fluid passage connection 430 for sealingly connecting to a corresponding connector in the first portion 130 of the storage compartment by an interference seal, thereby providing a sealed liquid passage between the first portion 130 and the second portion 135 of the storage compartment.

[0093] FIG. 5a is a perspective view of the assembled cartridge shown in FIG. 3, while an exploded view thereof is also provided in FIG. 5b. In FIG. 5a, removable seal 310 is positioned within air passage 140 with its seal portion 320 positioned outside heater element 121 and tab portion 330 extending beyond the cartridge housing. As shown in FIG. 5b, removable seal 310 is shown to have an "L"-shaped profile. That is, removable seal 310 is bent so that tab portion 330 is disposed perpendicular to seal portion 320 and thus conforms to the exterior contour of cartridge housing 105. This ensures the manufacture of a more compact cartridge.

[0094] Prior to its first use, a user may grasp the top of the tab portion 330 and pull it outwardly, away from the housing 105, to remove the removable seal 310 from the air passageway. This causes the airtight seal between the seal portion 320 and the heater element 121 to break and allows exposure of the liquid substrate from the second portion 135 of the storage compartment to the atmosphere. Once the removable seal is removed, a user may connect the connecting end 115 of the cartridge 100 to the corresponding connecting end 205 of the control body 200.

[0095] The removable seal also prevents dirt and dust from accumulating in the airflow passage 140 and heater element. Additionally, the tab portion 330 also prevents the cartridge from accidentally connecting onto the control body 200 before the tab portion is removed, because the tab portion 330 prevents connection unless removed. More specifically, the tab portion 330 prevents the heater element from being activated before the removable seal is removed.

[0096] 5b illustrates an exploded view of the exemplary cartridge of FIG. 3. A first portion of the storage compartment is integrally manufactured with the cartridge housing 105 by an injection molding process. The heater assembly 120 is manufactured by first molding a heater element with the heater assembly 120, which is integrally formed with the second portion of the storage compartment 135. The heater assembly 120 includes electrical contact pads for providing electrical connection to the control circuit 220.

[0097] The retention material 139 and capillary material 136 are then inserted into the second portion 135 of the storage compartment before the second portion 135 is closed by an end cap 138. The retention material 139 is a fibrous material provided to contain any liquid substrate entering from the first portion 130 before it is drawn toward the capillary material and consumed in the heater element. The end cap 138 is sealingly attached onto the second portion 135 by an interference fit to not only prevent leakage and evaporation of the liquid substrate from the second portion 135 of the storage compartment, but also to retain the capillary material contained within the second portion.

[0098] A removable seal is then positioned over the exterior of the heater element to seal it in place. While a mechanical sealing means 340 is used in this exemplary embodiment, the sealing portion 320 of the removable seal 310 may be secured onto the heater element by other cap sealing mechanisms, such as induction sealing or adhesive sealing. The seal joint 410 may then be installed onto the heater assembly 120 by an interference fit to form the example shown in Figures 4a and 4b. The use of the seal joint 410 is particularly beneficial because the heater element is fully exposed during application of the cap seal, thus providing sufficient free space for an induction or heat sealer to operate on the cap seal.

[0099] The completed heater assembly 120, with the seal joint 410 attached, is fitted onto the cartridge housing 105 via an interference fit to form the cartridge, as shown in Figures 3 and 5a.

[0100] FIG. 6 illustrates another embodiment in accordance with the present invention, but without the removable seal 310. As shown in FIG. 6, the cartridge 100 is similar in structure to the examples shown in FIGS. 3-5, and as such, the removable seal 310 can be applied in a similar manner. More specifically, the embodiment shown in FIG. 6 includes a storage compartment first portion 130 integrally formed with the housing 105, a heater assembly integrally formed with the storage compartment second portion 135, and an end cap 138 designed to cooperate directly with the housing 105 via an interference fit. That is, the end cap 138 of FIG. 6 is designed to snap onto the housing 105 in place of the heater assembly as shown in FIGS. 3 and 5. This further simplifies the manufacturing process.

[0101] It will also be apparent that alternative geometries are possible within the scope of the present invention: the cartridge and liquid storage compartment may have different cross-sectional shapes, and the heater assembly may have different shapes and configurations.

Claims

1. 1. A cartridge for an aerosol generation system, comprising: a housing having an opening at a mouth end and an air inlet; a storage compartment within the housing and configured to contain a liquid aerosol-forming substrate; an airflow passage extending from the air inlet to an opening at the mouth end; a fluid-permeable aerosol generation element within the housing and having a first surface and a second surface opposite the first surface, the second surface being in fluid communication with the storage compartment; A cartridge comprising: a removable seal having a sealing portion and a tab portion connected to the sealing portion, wherein the sealing portion is positioned within an airflow passage outside the first surface of the fluid-permeable aerosol generating element, and the tab portion extends outward from the housing through the air intake port.

2. 2. The cartridge of claim 1, wherein removal of the sealing portion from outside the first surface by applying a pulling force to the tab portion places the airflow passage in fluid communication with the first surface.

3. 3. The cartridge of claim 2, wherein the removable seal includes a retaining means for retaining the removable seal outside the airflow passage until the pulling force is applied to the tab portion.

4. A cartridge according to any one of claims 1 to 3, wherein the removable seal is removable from the air flow passage through the air inlet.

5. A cartridge according to any preceding claim, wherein the tab portion is flexible and configured to bend at the air inlet so as to match the external profile of the housing.

6. A cartridge according to any one of claims 1 to 5, wherein the sealing portion is arranged to provide an airtight seal between the fluid-permeable aerosol generating element and the airflow passage.

7. 7. The cartridge of claim 1, wherein the storage compartment comprises a first compartment and a second compartment interconnected by a connector, whereby liquid in the first compartment can pass to the second compartment through a liquid passage of the connector, and the first surface of the fluid-permeable aerosol-generating element faces the first compartment, the second surface faces the second compartment, and the second surface is in fluid communication with the second compartment, whereby liquid aerosol-forming substrate in the first compartment can reach the fluid-permeable aerosol-generating element only through the second compartment.

8. The cartridge of claim 7 , wherein the connector and the first surface of the fluid-permeable aerosol generating element define at least a portion of the airflow passage.

9. 9. A cartridge according to claim 7 or claim 8, wherein the airflow passage extends from the air inlet to an opening in the mouth end and between the first compartment and the second compartment.

10. A cartridge according to any one of claims 7 to 9, wherein the first compartment is located between the fluid-permeable aerosol-generating element and the opening in the mouth end.

11. The cartridge of any one of claims 7 to 10, wherein the connector is connected to the first compartment and / or the second compartment by an interference fit.

12. The cartridge of any one of claims 1 to 11, wherein the fluid-permeable aerosol-generating element is a heater element.

13. 13. The cartridge of claim 12, comprising a heater assembly comprising the heater element and an electrical contact portion electrically connected to the heater element, the contact portion being exposed through a connection end of the cartridge.

14. The cartridge of claim 13 , wherein the storage compartment includes a heater mount, the heater mount being molded to the exterior of the heater assembly.

15. 1. A cartridge for an aerosol generation system, comprising: a housing having an opening at a mouth end and an air inlet; a storage compartment within the housing and configured to contain a liquid aerosol-forming substrate, the storage compartment having a first compartment and a second compartment interconnected by a connector such that liquid in the first compartment can pass to the second compartment through a liquid passage in the connector; an airflow passage extending from the air inlet to an opening at the mouth end, the airflow passage passing between the first compartment and the second compartment; a fluid-permeable aerosol-generating element having a first surface and a second surface opposite the first surface, the first surface of the fluid-permeable aerosol-generating element facing the first compartment and the second surface facing the second compartment, the second surface being in fluid communication with the second compartment, such that a liquid aerosol-forming substrate in the first compartment can only reach the fluid-permeable aerosol-generating element through the second compartment, and the first surface and the connector forming part of the airflow passage; A cartridge wherein the liquid aerosol-forming substrate in the first compartment can reach the fluid-permeable aerosol-generating element only through the connector and the second compartment.

16. An aerosol generation system comprising a cartridge according to any one of claims 1 to 15 and a control body connected to the cartridge, the control body being configured to control the supply of power to the fluid-permeable aerosol generation element.

17. 1. An aerosol generating system comprising: a housing having an opening at a mouth end and an air inlet; a storage compartment within the housing and configured to contain a liquid aerosol-forming substrate; an airflow passage extending from the air inlet to an opening at the mouth end; a fluid-permeable aerosol generation element within the housing and having a first surface and a second surface opposite the first surface, the second surface being in fluid communication with the storage compartment; a removable seal having a sealing portion and a tab portion connected to the sealing portion, the sealing portion being positioned within the airflow passage outside the first surface of the fluid-permeable aerosol generating element, and the tab portion extending outward from the housing through the air inlet; a control body configured to control the supply of power to the fluid-permeable aerosol generating element.

Images