HEATER ASSEMBLY HAVING A SEALED AREA

Abstract

and providing a heater assembly for an aerosol generating system having a reservoir for holding a liquid aerosol-forming substrate. [Solution] A heater assembly for an aerosol generating system including a reservoir for holding a liquid aerosol-forming substrate, the heater assembly comprising a heating element and an open porous body coupled to the heating element, the open porous body configured to transport liquid from the reservoir to the heating element, and the open porous body including a sealed region configured to restrict the flow of liquid from the reservoir through the open porous body.

Description

[Technical Field]

[0001] The present disclosure relates to a heater assembly for an aerosol generation system. In particular, but not exclusively, the present disclosure relates to a heater assembly for a handheld, electrically operated aerosol generation system for heating an aerosol-generating substrate to generate an aerosol and deliver the aerosol to a user's mouth. The present disclosure further relates to a cartridge and an aerosol generation system including the heater assembly, as well as to a method of manufacturing the heater assembly. [Background technology]

[0002] Aerosol generating systems that heat a liquid aerosol-forming substrate to generate an aerosol for delivery to a user are generally known in the art. These systems typically include an aerosol generating device and a replaceable cartridge. The cartridge contains a liquid aerosol-forming substrate that can release a volatile compound when heated. The cartridge also typically includes a heater for heating the liquid aerosol-forming substrate. In known aerosol generating systems, the heater includes a resistive heating element wound around a wick that supplies the liquid aerosol-forming substrate to the heating element. The aerosol generating device or cartridge also includes a mouthpiece. When negative pressure is applied to the mouthpiece, electrical current flows through the heating element, heating the heating element by resistive or Joule heating, which in turn heats the liquid aerosol-forming substrate supplied by the wick. This releases the volatile compound from the liquid aerosol-forming substrate, which cools to form an aerosol. The aerosol is then drawn into the user's mouth through the mouthpiece.

[0003] Such known aerosol generating systems have many drawbacks. For example, they are difficult to manufacture with consistent manufacturing tolerances, which can result in inconsistent vapor production and flavor generation. These manufacturing tolerances can also affect heat transfer from the heating element to the wick, reducing the energy efficiency of such devices. Another problem encountered with such known aerosol generating systems is "dry heating" or "dry puffs," which occur when the heating element is heated with insufficient liquid aerosol-forming substrate supplied to the heating element. This can occur, for example, when a user consumes all the liquid aerosol-forming substrate in a cartridge, causing the cartridge to become depleted and require replacement. It is preferable to maintain a supply of liquid aerosol-forming substrate to the heating element so that the heating element remains moist during operation, as this helps ensure satisfactory aerosol generation when negative pressure is applied to the mouthpiece. Dry heating can result in overheating of the heating element and potentially thermal decomposition of the liquid aerosol-forming substrate, which can generate undesirable by-products and can produce an unsatisfactory aerosol. Allowing the aerosol-generating system to continue operating when no liquid aerosol-forming substrate is being supplied to the heating element can degrade the user experience.

[0004] Some aerosol generation systems include cartridges that utilize a heater assembly in the form of a ceramic atomizer core, which is composed of a heating element, electrical contacts, and a ceramic atomizer body. The ceramic body is porous, and the liquid aerosol-forming substrate is supplied from the cartridge's reservoir to the heating element through open pores present in the ceramic atomizer body. The pores in the ceramic atomizer body must be large enough to allow sufficient flow of liquid to the heating element and to allow the ceramic atomizer body to have sufficient liquid-holding capacity to prevent "dry burn," "dry heating," or "dry puff" conditions, which can lead to undesirable by-product emissions, unsatisfactory aerosols, and a poor user experience. However, if the pore size of the ceramic atomizer body is too large, too much liquid may be supplied to the heater surface, resulting in the undesirable effect of liquid leakage from the aerosol generation system. To address this issue, some aerosol generation systems utilize additional fluid communication channels between the liquid aerosol-forming substrate reservoir and the porous ceramic atomizer body. In this way, the size and number of fluid communication channels control the rate at which the liquid aerosol-forming substrate can flow into the ceramic atomizer body and then through the ceramic pores to the heater surface. However, such solutions rely on the use of additional components to create the fluid communication channels, which can add additional size, complexity, and cost to the aerosol generation system.

[0005] It would be desirable to provide a heater assembly that has the ability to produce a more consistent aerosol. It would be desirable to provide a heater assembly that reduces the likelihood that a user will experience liquid leakage while using the aerosol generating system. It would be desirable to provide a heater assembly that reduces the likelihood that a user will experience dry heating or dry puffs, and that prevents a user from being able to continue using an aerosol generating system when no liquid aerosol-forming substrate is supplied to the heating element. Summary of the Invention

[0006] According to one embodiment of the present disclosure, there is provided a heater assembly for an aerosol generation system including a reservoir for holding a liquid aerosol-forming substrate. The heater assembly may include a heating element for heating the liquid aerosol-forming substrate to form an aerosol. The heater assembly may include an open porous body for supplying the liquid aerosol-forming substrate to the heating element. The open porous body may include a sealed region configured to restrict flow of the liquid aerosol-forming substrate from the reservoir through the open porous body.

[0007] According to one embodiment of the present disclosure, there is provided a heater assembly for an aerosol generation system comprising a reservoir for holding a liquid aerosol-forming substrate. The heater assembly comprises a heating element for heating the liquid aerosol-forming substrate to form an aerosol. The heater assembly includes an open porous body for supplying the liquid aerosol-forming substrate to the heating element. The open porous body comprises a sealed region configured to restrict flow of the liquid aerosol-forming substrate from the reservoir through the open porous body.

[0008] Advantageously, providing a sealed region on or within the open porous body allows for control of the rate at which the liquid aerosol-forming substrate is delivered from the reservoir to the heater element without relying on additional components between the reservoir and the open porous body to control the flow of the liquid aerosol-forming substrate. Furthermore, it can be difficult to manufacture an open porous body with a pore size optimized for a particular aerosol-generation system to minimize the risk of dry burnout and liquid leakage. The proposed heater assembly solution can be easily manufactured by first forming an open porous body with a relatively large pore size, which can then be selectively sealed based on the particular aerosol-generation system (e.g., based on the area of ​​the open porous body exposed to the liquid, the viscosity of the liquid aerosol-forming substrate in the reservoir, and the operating temperature of the aerosol-generation system).

[0009] As used herein, the term "aerosol-generating device" refers to a device that interacts with a liquid aerosol-forming substrate to generate an aerosol.

[0010] As used herein, the terms "cartridge" and "aerosol-generating cartridge" refer to a component that interacts with a liquid aerosol-forming device to generate an aerosol. The aerosol-generating cartridge contains or is configured to contain a liquid aerosol-forming substrate.

[0011] As used herein, the term "liquid aerosol-forming substrate" refers to a liquid substrate capable of releasing volatile compounds capable of forming an aerosol. Such volatile compounds can be released by heating the aerosol-forming substrate.

[0012] As used herein, "heating element" refers to a component that transfers thermal energy to a liquid aerosol-forming substrate. Of course, the heating element can be placed directly on the open porous body.

[0013] As used herein, the term "open porous body" refers to a component having a plurality of pores, at least some of which are interconnected. The open porous body is configured to contain a liquid within the plurality of pores.

[0014] As used herein, the term "sufficient" as used in the phrase "sufficient amount of liquid aerosol-forming substrate" refers to an amount of aerosol-forming substrate that, when present in the heating element, prevents a dry-heat or dry-puff condition.

[0015] As used herein, the term "sealed region" refers to a region of an open porous body that is liquid impermeable such that the flow of liquid through the sealed region is prevented.

[0016] The open porous body may define a series of capillaries. The open porous body may have a liquid absorption side and an aerosolization side. A heating element may be disposed along the aerosolization side of the open porous body. The open porous body may be configured to supply a liquid aerosol-forming substrate from the liquid absorption side to the aerosolization side of the open porous body. A sealing region may be disposed along the liquid absorption side of the open porous body to limit the rate of liquid absorption through the open porous body.

[0017] The open porous body may be a ceramic body. Alternatively, the open porous body may be one of a glass, plastic, or metal body. The open porous body may have a porosity of 30% to 70%.

[0018] In other embodiments, the sealing region may be porous, and in such embodiments, the sealing region may have a porosity that is less than the porosity of the open porous body to prevent the flow of liquid through the sealing region into the open porous body.

[0019] The sealed region can be formed across the outermost surface of the open porous body. By restricting the flow of liquid through the open porous body at the outermost surface, the liquid retention capacity of the open porous body can be maintained while limiting the maximum liquid flow rate into the open porous body. The liquid aerosol-forming substrate held within the open porous body can function as a buffer in the event of a disruption in the flow of the liquid aerosol-forming substrate between the reservoir and the open porous body. Thus, the heater assembly of the present disclosure can avoid both dry burn and liquid leaks within the aerosol generation system.

[0020] The sealing region may extend across a majority of the surface of the open porous body. For example, the sealing region may cover more than 50% of the surface of the open porous body. In one embodiment, the sealing region may extend across the entire surface of the open porous body. By providing a sealing region that extends across a larger surface of the open porous body, the degree to which liquid flow into the open porous body is restricted may be improved.

[0021] In one embodiment, the sealing region may extend continuously across the face of the open porous mass, thereby uniformly restricting the flow of liquid through the face into the open porous mass. In another embodiment, the sealing region may extend intermittently across the face of the open porous mass, forming regions that restrict and regions that do not restrict the flow of liquid into the open porous mass.

[0022] In one embodiment, the sealing region may extend at least partially into the pores of the open porous body. In some embodiments, the sealing region extends from the outer surface of the open porous body into the outermost pores of the open porous body. In some embodiments, the sealing region extends into the pores of the open porous body and completely blocks the flow of liquid through the pores. In other embodiments, the sealing region extends into the pores of the open porous body and partially blocks the pores, thereby reducing the effective size of the pores and consequently reducing the rate at which liquid can flow through the pores.

[0023] In one embodiment, the sealing region may have a thickness of more than 10 μm, hi one embodiment, the sealing region may have a thickness of less than 1 mm.

[0024] The sealing region can include an inorganic layer. The inorganic layer can be deposited across the outermost pores of the open porous body. The inorganic layer can include one of aluminum oxide, silicon oxide, magnesium oxide, barium oxide, calcium oxide, zirconium dioxide, or zinc oxide.

[0025] In one example, the sealed region may comprise a region in which the outermost pores of the open porous body are deformed to prevent liquid from flowing through the pores into the open porous body. Such an example may be particularly advantageous in that it does not require additional materials, but rather relies on the modification of the manufactured open porous body.

[0026] In one embodiment, the sealed region may comprise one or more fused portions of the outer surface of the open porous body. In such an embodiment, the sealed region may comprise the outermost pores of the open porous body that have been deformed to prevent the flow of liquid through the pores into the open porous body.

[0027] In one embodiment, the heating element may be bonded to a first surface of the open porous body. The sealing region may extend across at least one other surface of the open porous body. The at least one other surface may include a surface opposite the first surface. In another embodiment, the at least one other surface may include a surface adjacent to the first surface. The open porous body may have a cubic shape. In some embodiments, the at least one other surface may include each surface adjacent to the first surface. In some embodiments, the sealing region may extend across all remaining surfaces of the open porous body (e.g., each side surface and bottom surface in the case of a cubic open porous body). In some embodiments, the sealing region may cover each remaining surface of the open porous body.

[0028] Of course, alternative open porous bodies may be used and the location of the sealing region may be varied depending on the shape of the open porous body to effectively restrict the flow of liquid aerosol-forming substrate into the open porous body.

[0029] The liquid aerosol-forming substrate may be liquid at room temperature. The liquid 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 comprise tobacco. The liquid aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds that are released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may comprise a homogenised tobacco material. The liquid aerosol-forming substrate may comprise a non-tobacco-containing material. The liquid aerosol-forming substrate may comprise a homogenised plant-derived material.

[0030] The liquid aerosol-forming substrate may include 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 (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.

[0031] 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%, for example about 2%.

[0032] The heating element may be disposed on a porous outer surface of the open porous body. The porous outer surface on which the heating element is disposed may be substantially flat. The heating element may extend at least partially into the pores of the porous outer surface. The heater assembly may include a protective layer. The protective layer may be disposed to extend over at least a portion of the heating element to protect the heating element.

[0033] The heating element may be electrically connected to the electrical contacts. The heating element may be configured to heat the liquid aerosol-forming substrate as a potential difference is applied to the electrical contacts. The heating element may have one or more of a curved or serpentine shape. The heating element may include an electrically resistive heating element. The heating element may be made from any suitable conductive material. 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. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. 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 heating element may be made from stainless steel, for example, 300 series stainless steels such as AISI 304, 316, 304L, and 316L.

[0034] Additionally, the heating element may comprise a combination of the above materials. A combination of materials may be used to improve control of the resistance of the heating 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 another perspective, such as price, machinability, or other physical and chemical parameters. Advantageously, heating at a high resistance allows for more efficient use of the battery energy.

[0035] According to one embodiment of the present disclosure, there is provided a cartridge for an aerosol generation system. The cartridge may include a heater assembly. The cartridge may include a liquid reservoir configured to hold a liquid aerosol-forming substrate. The liquid reservoir may be arranged to deliver the liquid aerosol-forming substrate to a heating element opposite the heater assembly.

[0036] According to one embodiment of the present disclosure, there is provided a cartridge for an aerosol generation system, the cartridge including a heater assembly, a liquid reservoir configured to hold a liquid aerosol-forming substrate, the liquid reservoir arranged to deliver the liquid aerosol-forming substrate to a heating element opposite the heater assembly.

[0037] According to one embodiment of the present disclosure, there is provided an aerosol generation system, which may include a cartridge, an aerosol generator having a power supply for supplying power to a heating element, and a control circuit configured to control the supply of power from the power supply to the heating element.

[0038] According to one embodiment of the present disclosure, there is provided an aerosol generation system comprising: a cartridge; an aerosol generator having a power supply for supplying power to a heating element; and a control circuit configured to control the supply of power from the power supply to the heating element.

[0039] According to one embodiment of the present disclosure, there is provided a method of manufacturing a heater assembly for an aerosol-generating system including a reservoir for holding a liquid aerosol-forming substrate. The heater assembly may include a heating element coupled to an open porous body. The method may include applying a sealing region on a face of the open porous body to restrict the flow of liquid from the reservoir through the open porous body.

[0040] According to one embodiment of the present disclosure, there is provided a method of manufacturing a heater assembly for an aerosol-generating system including a reservoir for holding a liquid aerosol-forming substrate, the heater assembly including a heating element coupled to an open porous body, the method including applying a sealing region onto a surface of the open porous body to restrict the flow of liquid from the reservoir through the open porous body.

[0041] In some embodiments, the sealing region may be applied by spraying a slurry of precursor material onto the surface of the open porous body. The slurry may then undergo a sintering process to form a sealing layer over the open porous body. In some embodiments, the precursor material may include a silicate material.

[0042] In some embodiments, the sealing region may be applied onto the open porous body by physical vapor deposition. In other embodiments, the sealing region may be applied onto the open porous body by chemical vapor deposition. In some embodiments, after depositing the sealing material onto the open porous body, the exterior surface of the open porous body may be wiped clean so that the sealing material remains only within the pores of the open porous body.

[0043] In some embodiments, the sealed region comprises:

[0044] It is applied to open porous materials by melting the surface of the open porous body with a laser (or other heating device) and deforming the outermost pores within the open porous body.

[0045] In some examples, the method may include masking a region of a surface of the open porous body while applying a sealing region on the open porous body to maintain one or more regions on the open porous body.

[0046] In some embodiments where the heating element is bonded to a first surface of the open porous body, the method may include applying a sealing region over at least one other surface of the open porous body, which may include a surface opposite the first surface.

[0047] In other embodiments where the heating element is bonded to a first surface of the open porous body, the method may include applying a sealing region across at least one other surface of the open porous body. The at least one other surface may include a surface adjacent to the first surface. In some embodiments, the at least one other surface may include each surface adjacent to the first surface. In other embodiments, the at least one other surface may include the remaining surfaces of the open porous body.

[0048] In some embodiments, the sealing region may be applied over a majority of the surface of the open porous mass. In some embodiments, the sealing region may be applied over the entire surface of the open porous mass.

[0049] In some embodiments, the sealing region is applied over an open porous body having a thickness greater than 10 μm.

[0050] In some embodiments, the sealing region can include an inorganic layer applied across the outermost pores of the open porous body, hi some embodiments, the inorganic layer includes one of aluminum oxide, silicon oxide, magnesium oxide, barium oxide, calcium oxide, zirconium dioxide, or zinc oxide.

[0051] The open porous body may be produced by sintering, whereby the ceramic powder is directly sintered to form an open porous body with pores between interconnected powder particles. The open porous body may also be produced by using a sacrificial material within the ceramic powder, which is used as a spacer to form the pores. The sacrificial material may be burned away during sintering.

[0052] The aerosol generating system may be portable. The aerosol generating system may have a size comparable to that of a conventional cigar or cigarette.

[0053] The aerosol generating device may contain a control circuit. The control circuit may include any suitable controller or electrical component. The controller may include a memory. Information for implementing the above-described methods may be stored in the memory. The control circuit may include a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller, or an application-specific integrated chip (ASIC) or other electronic circuit capable of providing control. The control circuit may be configured to supply power to the heating element continuously after activation of the device, or may be configured to supply power intermittently, such as after each puff. Power may be supplied to the heating element in the form of current pulses, for example, by pulse-width modulation (PWM). The control circuit may include additional electronic components. For example, in some embodiments, the control circuit may include a sensor element, a switch element, or a display element.

[0054] The aerosol generating device may contain a power source in the form of a battery. The battery may be rechargeable. 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 be rechargeable and configured for numerous charge and discharge cycles. The power source may have a capacity that allows for the storage of energy sufficient for one or more user experiences with the aerosol generating system; for example, the power source may have a capacity sufficient to allow continuous generation of aerosol for approximately six minutes, corresponding to the typical time it takes to smoke one 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 aerosol generating system.

[0055] The aerosol generating device may include a housing. The housing may be elongated. The housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene. The material is preferably lightweight and non-brittle.

[0056] The cartridge may be removably connectable to the aerosol generating device.

[0057] The cartridge of the aerosol generation system may have a connecting end. At the connecting end, the cartridge may be connected or connectable to an aerosol generation device. The connecting end of the cartridge may have electrical contacts that are electrically connectable to electrical contacts on the aerosol generation device. The cartridge may include one or more of a mouthpiece, a cartridge body, an external air inlet, an internal air passage, and an aerosol outlet.

[0058] The mouthpiece may be connected or connectable to the cartridge body. The mouthpiece may be connected or connectable to the cartridge body so as to define one or more external air inlets between the mouthpiece and the cartridge body. The mouthpiece may be disposed at an end of the cartridge body. The mouthpiece may be disposed at an end of the cartridge body opposite the connected end. The mouthpiece may include an aerosol outlet.

[0059] The cartridge body may include a heater assembly. The cartridge body may include a liquid reservoir. The heater assembly may be located adjacent to or at the connecting end. The liquid reservoir may be located between the heater assembly and the mouthpiece.

[0060] The liquid reservoir may be disposed on a first side of the heater assembly. The airflow channel may be disposed on a side opposite the first side of the heater assembly. The airflow channel may be adjacent to the heating element. The airflow path may extend through the heating element. The airflow path may be configured to transport the aerosol. The cartridge body may be configured such that airflow passing through the heater assembly entrains the vaporized aerosol-forming substrate. The cartridge may be configured to allow air to flow from outside the system through the external air inlet and into the cartridge body. The cartridge may be configured such that the air can then flow toward the connecting end. At the connecting end, the air may be directed to turn back and flow through the center of the cartridge. In doing so, the airflow may pass through the heater assembly. At the heater assembly, the air may be combined with the aerosol. The cartridge may be configured such that, after being combined with the aerosol, the airflow passes through the center of the cartridge to the mouthpiece. The airflow may then pass out through the aerosol outlet opening.

[0061] The mouthpiece may include an internal baffle. The internal baffle may be integrally molded with the outer wall of the mouthpiece portion. The baffle may ensure that as air is drawn from the inlet to the aerosol outlet opening, it flows over a heater assembly on the cartridge where the aerosol-forming substrate is vaporized. As the air passes over the heater assembly, the vaporized substrate is entrained in the airflow and may cool before exiting the aerosol outlet opening, forming an aerosol.

[0062] Features described with respect to one of the above embodiments may equally be applied to other embodiments of the present disclosure. [Example]

[0063] 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.

[0064] Example 1: 1. A heater assembly for an aerosol generating device including a reservoir for holding a liquid aerosol-forming substrate, comprising: A heating element; an open porous body coupled to the heating element, the open porous body configured to transport liquid from the reservoir to the heating element; A heater assembly, wherein the open porous body includes a sealed region configured to restrict the flow of liquid from the reservoir through the open porous body. Example 2: 10. The heater assembly of example 1, wherein the sealed region extends across a majority of the surface of the open porous body. Example 3: 3. The heater assembly of any one of Examples 1 or 2, wherein the sealed region extends across the entire surface of the open porous body. Example 4: The heater assembly of any of Examples 1-3, wherein the sealed region has a thickness greater than 10 μm. Example 5: 5. The heater assembly of any of Examples 1-4, wherein the open porous body comprises one of a ceramic, glass, plastic, or metal body. Example 6: 6. The heater assembly of any one of Examples 1 to 5, wherein the open porous body has a porosity of 30 to 70%. Example 7: 7. The heater assembly of any of Examples 1-6, wherein the sealing region comprises an inorganic layer deposited across the outermost pores of the open porous body, the inorganic layer comprising one of aluminum oxide, silicon oxide, magnesium oxide, barium oxide, calcium oxide, zirconium dioxide, or zinc oxide. Example 8: 8. The heater assembly of any one of Examples 1 to 7, wherein the open porous body comprises a sintered ceramic material. Example 9: The heater assembly of any one of Examples 1 to 8, wherein the heating element is electrically connected to an electrical contact. Example 10: 10. The heater assembly of example 9, wherein the heating element is configured to heat the liquid aerosol-forming substrate when a potential difference is applied across the electrical contacts. Example 11: 1. A cartridge for an aerosol generation system, comprising: A heater assembly according to any one of Examples 1 to 10; a liquid reservoir configured to hold a liquid aerosol-forming substrate. Example 12: 1. An aerosol generating system comprising: A cartridge as described in Example 11; An aerosol generating system comprising: an aerosol generating device. Example 13: 1. A method for manufacturing a heater assembly for an aerosol-generating device including a reservoir for holding a liquid aerosol-forming substrate, the heater assembly comprising a heating element coupled to an open porous body; A method comprising applying a sealing region across a face of the open porous body to restrict the flow of liquid from the reservoir through the open porous body. Example 14: Applying a sealing area spraying a slurry of precursor material onto a surface of the open porous body; sintering the slurry to form a sealing layer over the open porous body. Example 15: 15. The method of any of Examples 13-14, wherein the precursor material comprises a silicate material. Example 16: 14. The method of any of Examples 13, wherein applying the sealing region comprises physical vapor deposition. Example 17: 14. The method of any of Examples 13, wherein applying the sealing region comprises chemical vapor deposition. Example 18: 14. The method of any of example 13, wherein applying the sealing region comprises melting the outer surface of the open porous body to cause deformation of the outermost pores. Example 19: 19. The method of any of Examples 13-18, wherein the method comprises masking an area on the face of the open porous body while applying a sealing area. Example 20: A heating element is bonded to a first surface of the open porous body, and the method comprises: 20. The method of any of Examples 13-19, comprising applying a sealed region over at least one other surface of the open porous body, the at least one other surface comprising a surface opposite the first surface. Example 21: A heating element is bonded to a first surface of the open porous body, and the method comprises: 21. The method of any of Examples 13-20, comprising applying a sealed region over at least one other surface of the open porous body, wherein the at least one other surface comprises a surface adjacent to the first surface. Example 22: 22. The method of any of Examples 21, wherein the open porous body has a cubic shape and the at least one other face includes each face adjacent to the first face. Example 23: 23. The method of any of Examples 13-22, wherein the heating element is bonded to a first surface of the open porous body and a sealed region is provided across the remaining surface of the open porous body. Example 24: 24. The method of any of Examples 13-23, wherein the sealed region extends across a majority of the surface of the open porous body. Example 25: 25. The method of any of Examples 13-24, wherein the sealed region extends across the entire surface of the open porous body. Example 26: 26. The method of any of Examples 13-25, wherein the sealed region extends continuously across the face of the open porous body. Example 27: 26. The method of any of Examples 13-25, wherein the sealed region extends intermittently across the face of the open porous body. Example 28: The method of any of Examples 13-27, wherein the sealed region extends at least partially into the pores of the open porous body. Example 29: The method of any of Examples 13 to 27, wherein the sealed region is porous and has a porosity that is lower than the porosity of the open porous body. Example 30: The method of any one of Examples 13 to 29, wherein the sealing region has a thickness greater than 10 μm. Example 31: The method of any of Examples 13-30, wherein the sealing region has a maximum thickness of 1 mm. Example 32: The method of any of Examples 13-31, wherein the sealed region comprises an inorganic layer deposited across the outermost pores of the open porous body. Example 33: 33. The method of example 32, wherein the inorganic layer comprises one of aluminum oxide, silicon oxide, magnesium oxide, barium oxide, calcium oxide, zirconium dioxide, or zinc oxide. Example 34: 34. The method of any of Examples 13-33, wherein the open porous body comprises one of a ceramic, glass, plastic, or metal body. Example 35: The method according to any one of Examples 13 to 34, wherein the open porous body has a porosity of 30 to 70%.

[0065] The embodiments will now be further described with reference to the figures. [Brief explanation of the drawings]

[0066] [Figure 1a] FIG. 1 is an isometric view of a heater assembly according to one embodiment of the present disclosure. [Figure 1b] FIG. 1b is a schematic diagram of an open porous body according to one embodiment of the present disclosure. [Figure 2a] FIG. 2a is a schematic diagram of a heater assembly according to one embodiment of the present disclosure, including a sealed region on a face of an open porous body opposite a face containing a heating element. [Figure 2b] FIG. 2b is a schematic diagram of a heater assembly according to one embodiment of the present disclosure, including intermittent sealed regions along the sides of the open porous body. [Figure 2c] FIG. 2c is a schematic diagram of a heater assembly according to one embodiment of the present disclosure, including intermittent sealed regions around the sides and bottom of the open porous body. [Figure 2d] FIG. 2d is a schematic diagram of a heater assembly according to one embodiment of the present disclosure, including sealed regions extending along portions of each of the side and bottom surfaces of the open porous body. [Figure 2e] FIG. 2e is a schematic diagram of a heater assembly according to one embodiment of the present disclosure, including a sealed region that extends at least partially into the pores of the open porous medium. [Figure 2f] FIG. 2f is a schematic diagram of a heater assembly according to one embodiment of the present disclosure, including sealed regions within the pores of an open porous body. [Figure 3] FIG. 3 is a schematic diagram of a cartridge having a heater assembly according to one embodiment of the present disclosure. [Figure 4] FIG. 4 is a schematic diagram of an aerosol generation system according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0067] The above and other features and advantages of the exemplary embodiments will become more apparent from the detailed description of the exemplary embodiments with reference to the accompanying drawings. However, the specific structural and functional details disclosed herein are merely representative for purposes of describing the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited to only the embodiments set forth herein.

[0068] As a result, while exemplary embodiments are susceptible to various modifications and alternative forms, such embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed, but on the contrary, the exemplary embodiments are intended to cover all modifications, equivalents, and alternatives falling within the scope of the exemplary embodiments. Like numerals refer to like elements throughout the description of the figures.

[0069] Spatial relationship terms (e.g., "below") may be used herein for ease of description to describe the relationship between one element or feature and another element or feature as shown in the figures. Of course, spatial relationship terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures were turned upside down, an element described as "below" another element or feature would then be oriented "above" the other element or feature. Thus, the term "below" may encompass both an orientation of above and below. The device may be oriented otherwise (rotated 90 degrees or at other orientations), and the spatial relationship descriptors used herein will be interpreted accordingly.

[0070] When an element or layer is referred to as "disposed on" another element or layer, it should be understood that the element or layer may be directly on, directly connected to, directly bonded to, or directly covering the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as "disposed directly on" another element or layer, there are no intervening elements or layers present.

[0071] The terminology used herein is for the purpose of describing various embodiments only and is not intended to limit example embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise. It will be further understood that the terms "includes," "including," "comprises," and "comprising," when used herein, specify the presence of stated features, integers, steps, operations, or elements, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, or groups thereof.

[0072] The exemplary embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the exemplary embodiments. As such, variations from the illustrated shapes, resulting, for example, from manufacturing techniques or tolerances, are expected. Accordingly, the exemplary embodiments should not be construed as limiting the shapes of regions illustrated herein and are intended to include deviations in shape that result, for example, from manufacturing. Accordingly, the regions illustrated in the figures are schematic in nature, and their shapes are not intended to illustrate the actual shapes of regions of a device and are not intended to limit the scope of the exemplary embodiments. Like reference numerals refer to like elements throughout the figures. The accompanying drawings should not be considered to scale unless expressly noted. It is understood that the drawings in the present application are schematic, with some features omitted for clarity.

[0073] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the exemplary embodiments belong. It should further be understood that terms (including terms defined in commonly used dictionaries) should be interpreted to have a meaning consistent with the meaning of those terms in the context of the relevant art, unless expressly so defined herein, and should not be interpreted in an idealized or overly formal sense.

[0074] The accompanying drawings are intended to depict exemplary embodiments and are not to be construed as limiting the scope of the intended claims.

[0075] 1a, a schematic diagram of a heater assembly 100 for an induction heated aerosol generation system according to one embodiment of the present disclosure is shown. The heater assembly 100 includes an open porous body 110, a heating element 120, electrical contacts 130, and a sealing region 150 applied to the side of the open porous body 110.

[0076] The open porous body 110 is configured to supply the liquid aerosol-forming substrate to the heating element 120. Specifically, the open porous body 110 is configured to transfer the liquid aerosol-forming substrate from a liquid reservoir (not shown in FIG. 1 for clarity) to the heating element 120. The open porous body 110 is configured to store a portion of the liquid aerosol-forming substrate until it is aerosolized by the heating element 120.

[0077] As shown in FIG. 1b, the open porous body 110 is a rectangular parallelepiped block. The open porous body 110 includes a plurality of pores 140. The plurality of open pores 140 are interconnected and provide a fluid path for the aerosol-generating liquid through the open porous body 110. The open porous body 110 includes a material that does not chemically interact with the liquid aerosol-forming substrate. The open porous body 110 includes a ceramic. The open porous body 110 includes Ca2SiO3 or SiO2 (or Ca2SiO3 and SiO2). Of course, the open porous body 110 may have a different shape or include a different material. In other embodiments, the open porous body 110 includes one of glass, plastic, or metal.

[0078] A heating element 120 is provided over the top surface of the open porous body 110. The heating element 120 is configured to heat the liquid aerosol-forming substrate to form an aerosol. The heating element 120 is configured to convert electrical energy into thermal energy and then electrical current, via the material resistance of the heating element 120.

[0079] The heating element 120 has an elongated shape. The heating element 120 comprises NiCr or TiZr (or NiCr and TiZr). Of course, the heating element 120 may have a different shape or comprise a different material.

[0080] The heating element 120 is disposed along the porous outer surface of the open porous body 110. The heating element 120 is in direct contact with the open porous body 110. The heating element 120 is disposed on a single surface of the open porous body 110.

[0081] The heating element 120 is electrically connected to the electrical contacts 130. The heating element 120 is configured to heat the liquid aerosol-forming substrate when a potential difference is applied across the electrical contacts 130. The electrical contacts 130 are disposed at each end of the elongated heating element 120. The electrical contacts 130 are disposed directly on the same surface of the open porous body 110 as the heating element 120. The electrical contacts 130 comprise CuZnAu. The electrical contacts 130 are disposed at opposite ends of the porous outer surface of the open porous body 110. The electrical contacts 130 are aligned with opposite ends of the porous outer surface of the open porous body 110.

[0082] The sealed region 150 extends continuously across the side of the open porous body 110 adjacent the side comprising the heating element 120. The sealed region 150 is configured to restrict the flow of liquid through the open porous body 110 to the heating element 120. In the embodiment of Figure 1a, the flow of liquid through the sides of the open porous body 110 is prevented, while the flow of liquid through the bottom surface of the open porous body is unrestricted.

[0083] 2a-2f illustrate embodiments of the heater assembly 100 having alternative sealing region arrangements. FIG. 2a illustrates an example in which the sealing region 150 extends continuously across the bottom surface of the open porous mass 110 opposite the surface comprising the heating element 120. FIG. 2b illustrates an example in which the sealing region 150 extends intermittently across the side surface of the open porous mass 110 adjacent to the surface comprising the heating element 120. FIG. 2c illustrates an example in which the sealing region 150 extends intermittently across the side and bottom surfaces of the open porous mass 110, thereby restricting the flow of liquid through both the side and bottom surfaces of the open porous mass 110. FIG. 2d illustrates an example in which the sealing region 150 extends across some (but not all) of the side and bottom surfaces of the open porous mass 110. FIG. 2e illustrates an example in which the sealing region 150 extends continuously across the side surface of the open porous mass 110 and partially across the bottom surface of the open porous mass 110. The sealing region 150 in Figure 2e extends at least partially into the pores 140 of the open porous body 110 and restricts the flow of liquid into each pore 140 of the open porous body 110. Figure 2f illustrates an embodiment in which the sealing region 150 is located within the pores 140 across the sides of the open porous body 110 and in some of the pores 140 across the bottom of the open porous body 110 to restrict the flow of liquid into each pore 140 of the open porous body 110. In other embodiments, the sealing region 150 may be located only in some of the pores 140 across the sides of the open porous body 110, or in some of the pores 140 across the bottom of the open porous body 110.

[0084] In some embodiments, the sealing region 150 forms a liquid impermeable barrier across one or more pores 140 of the open porous body 110. In some embodiments, the sealing region 150 is porous and has a porosity that is lower than the porosity of the open porous body 110, thereby restricting the flow of liquid into the open porous body 110.

[0085] The sealing region 150 may include one or more of aluminum oxide, silicon oxide, magnesium oxide, barium oxide, calcium oxide, zirconium dioxide, or zinc oxide.

[0086] Of course, numerous alternative sealing region 150 configurations or materials can be utilized to restrict the flow of liquid through the open porous body 110 to the heating element 120. The positioning of the sealing region 150 on the open porous body 110 can be tailored to the particular aerosol-generating system to effectively control the flow of liquid aerosol-forming substrate through the open porous body 110 to the heating element 120.

[0087] 3 and 4, there is shown a schematic diagram of an exemplary aerosol generation cartridge 400 and a schematic diagram of an exemplary aerosol generation system 600. The aerosol generation system 600 comprises two main components: the cartridge 400 and the main body or aerosol generation device 500.

[0088] The aerosol-generating cartridge 400 includes a heater assembly 100 and liquid reservoirs 430, 435 configured to hold a liquid aerosol-forming substrate, the liquid reservoirs 430, 435 being disposed opposite the porous outer surface of the heater assembly.

[0089] The aerosol generation system 600 comprises the cartridge 400, a power supply 510 for supplying power to the heating element, and a control circuit 520 configured to control the supply of power from the power supply 510 to the heating element.

[0090] A connecting end 415 of the cartridge 400 is removably connected to a corresponding connecting end 505 of the aerosol generation device 500. The connecting end 415 of the cartridge 400 and the connecting end 505 of the aerosol generation device 500 each have electrical contacts or connections (not shown) arranged to cooperate to provide an electrical connection between the cartridge 400 and the aerosol generation device 500. The aerosol generation device 500 includes a power source in the form of a battery 510, which in this example is a rechargeable lithium-ion battery, and a control circuit 520. The aerosol generation system is portable and has a size comparable to that of a conventional cigar or cigarette. A mouthpiece 425 is disposed at the end of the cartridge 400 opposite the connecting end 415.

[0091] The cartridge 400 comprises a housing 405 including the heater assembly 100 of FIG. 1a or 2a-f and a liquid storage compartment or portion having a first storage portion 430 and a second storage portion 435. A liquid aerosol-forming substrate is held in the liquid storage compartment. Although not shown in FIG. 3 or 4, the first storage portion 430 of the liquid storage compartment is connected to the second storage portion 435 of the liquid storage compartment such that liquid in the first storage portion 430 can transfer to the second storage portion 435. The heater assembly 100 receives liquid from the second storage portion 435 of the liquid storage compartment. At least a portion of the open porous body of the heater assembly 100 extends into the second storage portion 435 of the liquid storage compartment and contacts the liquid aerosol-forming substrate therein.

[0092] Airflow passages 440, 445 extend from an air inlet 450 formed in the side of the housing 405, past the heating element of the heater assembly 100, and from the heater assembly 100 through the cartridge 400 to a mouthpiece opening 410 formed in the housing 405 at the end of the cartridge 400 opposite the connecting end 415.

[0093] The components of the cartridge 400 are arranged so that the first storage portion 430 of the liquid storage compartment is between the heater assembly 100 and the mouthpiece opening 410, and the second storage portion 435 of the liquid storage compartment is positioned on the heater assembly 100 opposite the mouthpiece opening 410. In other words, the heater assembly 100 is positioned between the two portions 430, 435 of the liquid storage compartment and receives liquid from the second storage portion 435. The first storage portion 430 of the liquid storage compartment is closer to the mouthpiece opening 410 than the second storage portion 435 of the liquid storage compartment. Airflow passages 440, 445 extend past the heating element of the heater assembly 100 and between the first storage portion 430 and the second storage portion 435 of the liquid storage compartment.

[0094] The aerosol generation system is configured so that negative pressure can be applied at the mouthpiece 425 of the cartridge, drawing aerosol out through the mouthpiece opening 410. In operation, when negative pressure is applied at the mouthpiece 425, air is drawn from the air inlet 450 through the airflow passages 440, 445, past the heater assembly 100, and into the mouthpiece opening 410. A control circuit 520 controls the supply of power from the battery 510 to the cartridge 400 when the system is activated. This, in turn, controls the amount and characteristics of vapor produced by the heater assembly 100. The control circuit 520 may include an airflow sensor (not shown), and may supply power to the heater assembly 100 when a puff by the user is detected by the airflow sensor. This type of control is well established in aerosol generation systems such as inhalers and e-cigarettes. When negative pressure is applied to the mouthpiece opening 410 of the cartridge 400, the heater assembly 100 is activated and generates vapor that is entrained in the airflow passing through the airflow passage 440. The vapor cools within the airflow in the passage 445 to form an aerosol, which is then drawn through the mouthpiece opening 410 into the user's mouth.

[0095] In operation, the mouthpiece opening 410 is typically the highest point in the system. The construction of the cartridge 400, and in particular the arrangement of the heater assembly 100 between the first storage portion 430 and the second storage portion 435 of the liquid storage compartment, is advantageous because it utilizes gravity to ensure that liquid substrate is delivered to the heater assembly 100 even as the liquid storage compartment begins to empty, but prevents oversupply of liquid to the heater assembly 100, which could lead to leakage of liquid into the airflow passage 440.

[0096] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A ± ten percent (10%) A. Within this context, the number A may be considered to include values ​​that are within the typical standard error for measurement of the property it modifies. In some instances, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. 1. A heater assembly for an aerosol generating device including a reservoir for holding a liquid aerosol-forming substrate, comprising: A heating element; an open porous body coupled to the heating element, the open porous body being configured to transport liquid from the reservoir to the heating element; A heater assembly, wherein the open porous mass includes a sealed region configured to restrict flow of the liquid from the reservoir through the open porous mass.

2. 2. The heater assembly of claim 1, wherein the heating element is bonded to a first surface of the open porous body, and the sealed region extends across at least one other surface of the open porous body, the at least one other surface including a surface opposite the first surface.

3. 2. The heater assembly of claim 1, wherein the heating element is bonded to a first surface of the open porous body, and the sealed region extends across at least one other surface of the open porous body, the at least one other surface including a surface adjacent to the first surface.

4. 4. The heater assembly of claim 3, wherein said open porous body has a cubic shape and said at least one other face includes each face adjacent said first face.

5. The heater assembly of claim 1 , wherein the heating element is bonded to a first surface of the open porous body and the sealed region extends across a remaining surface of the open porous body.

6. A heater assembly according to any preceding claim, wherein the sealed region extends continuously across the surface of the open porous body.

7. A heater assembly according to any preceding claim, wherein the sealed region extends discontinuously across the face of the open porous body.

8. A heater assembly according to any preceding claim, wherein the sealed region extends at least partially within the pores of the open porous body.

9. The heater assembly of any preceding claim, wherein the sealing area has a thickness of 1 mm or less.

10. A heater assembly according to any preceding claim, wherein the sealing region is porous and has a porosity lower than the porosity of the open porous body.

11. A heater assembly according to any preceding claim, wherein the sealed region comprises an inorganic layer deposited across the outermost pores of the open porous body.

12. A heater assembly according to any preceding claim, wherein the sealed region comprises the deformed outermost pores of the open porous body.

13. A cartridge comprising the heater assembly of any one of claims 1 to 12 and a reservoir for holding a liquid aerosol-forming substrate.

14. An aerosol generation system comprising the cartridge of claim 13 and an aerosol generation device.

15. 1. A method for manufacturing a heater assembly for an aerosol-generating device including a reservoir for holding a liquid aerosol-forming substrate, the heater assembly comprising a heating element coupled to an open porous body; applying a sealing region across a face of the open porous body to restrict the flow of the liquid from the reservoir through the open porous body.

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