Heater assembly, aerosol supply system, and method

Abstract

A heater assembly for an aerosol supply system is described, defining a three-dimensional object having multiple outer surfaces. The heater assembly includes a substrate, a heater layer configured to generate heat when energy is supplied, the heater layer provided on the substrate at a first outer surface of the heater assembly, one or more capillaries extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, the one or more capillaries for supplying aerosol-generating material to the heater layer for vaporization, the second outer surface being substantially opposite to the first outer surface, and one or more distribution channels extending from a third outer surface of the substrate to at least one capillary for supplying aerosol-generating material to the one or more capillaries. The third outer surface is a side surface of the heater assembly, the side surface sharing an edge with at least one of the first and second outer surfaces, the distance from the center of the third outer surface to the center of the heater assembly is shorter than the distance from the center of any other side surface of the heater assembly to the center of the heater assembly. Methods for manufacturing aerosol supply systems and heater assemblies are also described.

Description

Technical Field

[0001] The present disclosure relates to an electronic aerosol supply system, such as a nicotine delivery system (e.g., an electronic cigarette, etc.).

Background Art

[0002] An electronic aerosol supply system, such as an electronic cigarette (e-cigarette), generally includes a reservoir of a feed liquid, typically containing nicotine, from which an aerosol is generated, for example by thermal vaporization. Thus, the aerosol source for the aerosol supply system may comprise a heater having a heating element configured to receive the feed liquid from the reservoir, for example by wicking / capillary action. While the user inhales on the device, power is supplied to the heating element to vaporize the feed liquid in the vicinity of the heating element and generate an aerosol for inhalation by the user. Such a device typically comprises one or more air inlet holes disposed away from the mouthpiece end of the system. When the user inhales on a mouthpiece connected to the mouthpiece end of the system, air is drawn through the inlet holes and passes through the aerosol source. There is a flow path connecting between the aerosol source and an opening in the mouthpiece, whereby the inhaled air passing through the aerosol source continues to travel along the flow path to the mouthpiece opening, and along with that air, a portion of the aerosol from the aerosol source is carried. The air carrying the aerosol exits the aerosol supply system through the mouthpiece opening for inhalation by the user.

[0003] Typically, such an electronic aerosol supply system comprises a heater assembly suitable for heating the feed liquid to form an aerosol. However, an example of such a heater assembly is a wick and coil heater assembly, formed from a coil of wire (typically nichrome NiCr 8020) wound around or coiled around a wick (which typically comprises a bundle of collected fibers, such as cotton fibers, extending along the longitudinal axis of the coil of wire). The ends of the wick extend on both sides of the coil of wire and are inserted into the reservoir of the feed liquid.

[0004] However, such heater assemblies are not necessarily suitable for all applications or configurations of electronic aerosol delivery systems. Problems associated with these heater assemblies typically relate to the combustion or carbonization of the wick material, caused by the heater operating at too high a temperature, especially when insufficient liquid is supplied to the heater assembly. Furthermore, the performance characteristics of these heater assemblies are generally not considered optimal, and alternative solutions that can provide more optimal aerosol delivery are desired.

[0005] This document describes various techniques that attempt to help address some of these problems. [Overview of the project]

[0006] According to a first aspect of a particular embodiment, a heater assembly for an aerosol supply system is provided, the heater assembly defining a three-dimensional object having a plurality of outer surfaces. The heater assembly includes a substrate, a heater layer configured to generate heat when energy is supplied, the heater layer provided on the substrate at a first outer surface of the heater assembly, one or more capillaries extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, the one or more capillaries for supplying aerosol-generating material to the heater layer for vaporization, the second outer surface being substantially opposite to the first outer surface, and one or more distribution channels extending from a third outer surface of the substrate to at least one capillary for supplying aerosol-generating material to one or more capillaries. The third outer surface is a side surface of the heater assembly, which shares an edge with at least one of the first and second outer surfaces, and the distance from the center of the third outer surface to the center of the heater assembly is shorter than the distance from the center of any other side surface of the heater assembly to the center of the heater assembly.

[0007] According to a second aspect of a particular embodiment, an aerosol supply system is provided, which includes a heater assembly of the first aspect and an aerosol-generating material storage section for storing an aerosol-generating material, wherein the heater assembly is positioned relative to the aerosol-generating material storage section so that the aerosol-generating material can be supplied to a third outer surface.

[0008] According to a third aspect of a particular embodiment, a method is provided for manufacturing a heater assembly for an aerosol supply system, the heater assembly defining a three-dimensional object having a plurality of outer surfaces. The method includes the steps of: providing a substrate; providing a heater layer on the substrate on a first outer surface of the heater assembly, the heater layer being configured to generate heat when energy is supplied; providing one or more capillaries extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, the one or more capillaries being for supplying aerosol-generating material to the heater layer for vaporization, the second outer surface being substantially opposite to the first outer surface; and providing one or more distribution channels extending from a third outer surface of the substrate to at least one capillary for supplying aerosol-generating material to one or more capillaries. The third outer surface is a side surface of the heater assembly, which shares an edge with at least one of the first and second outer surfaces, and the distance from the center of the third outer surface to the center of the heater assembly is shorter than the distance from the center of any other side surface of the heater assembly to the center of the heater assembly.

[0009] According to a fourth aspect of a particular embodiment, a heater means for an aerosol supply system is provided, the heater means defining a three-dimensional object having a plurality of outer surfaces. The heater means includes a substrate, a heater layer means configured to generate heat when energy is supplied, provided on the substrate at a first outer surface of the heater means, a capillary means extending from a second outer surface of the heater means through the heater layer means provided on the first outer surface of the heater means, the capillary means for supplying an aerosol-generating material to the heater layer means for vaporization, the second outer surface being substantially opposite to the first outer surface, and a distributor means extending from a third outer surface of the substrate to the capillary means for supplying an aerosol-generating material to the capillary means. The third outer surface is a side of the heater means, which shares an edge with at least one of the first and second outer surfaces, and the distance from the center of the third outer surface to the center of the heater means is shorter than the distance from the center of any other side of the heater means to the center of the heater means.

[0010] It will be understood that the features and embodiments of the present invention described above with respect to the first and other aspects of the present invention are equally applicable to, as appropriate, embodiments of the present invention according to other aspects of the present invention, not only in the specific combinations described above, but may also be combined with them.

[0011] Next, embodiments of the present invention will be described as merely examples with reference to the attached drawings. [Brief explanation of the drawing]

[0012] [Figure 1] This is a perspective view of an aerosol supply system according to an aspect of the present disclosure. [Figure 2] Figure 1 is a disassembled perspective view of a cartomizer suitable for use in an aerosol supply system. [Figure 3a] Figures 1 and 2 show a more detailed schematic of parts of the cartomizer, and Figure 3a shows a cross-sectional view of the lower part of the cartomizer. [Figure 3b]Figures 1 and 2 show a more detailed schematic of parts of the cartomizer, and Figure 3b shows a cross-sectional view of the lower surface of the upper clamp unit and heater assembly, in particular showing the elongated recess of the upper clamp unit. [Figure 4] This is a perspective view of a heater assembly according to a first aspect of the present disclosure, the heater assembly comprising a substrate, an electrical resistance layer, capillaries extending through the substrate and the electrical resistance layer, and one or more distribution channels formed by interconnected pores within the substrate. [Figure 5] This is a perspective view of a heater assembly according to a second aspect of the present disclosure, the heater assembly comprising a substrate, an electrical resistance layer, capillaries extending through the substrate and the electrical resistance layer, and one or more distribution channels formed in the substrate by engineering processes. [Figure 6] A top view of the heater assembly is shown, specifying various dimensions / distances from the side to the center of the heater assembly. [Figure 7a] A schematic representation of a second embodiment of the cartomizer, including a heater assembly, is shown, where the airflow crosses the heater layer of the heater assembly, and the entire side surface is exposed to the aerosol-generating material storage section. [Figure 7b] A schematic representation of a second embodiment of the cartomizer, including a heater assembly, is shown, where the airflow crosses the heater layer of the heater assembly, and the entire side surface is exposed to the aerosol-generating material storage section. [Figure 8] A method according to the present disclosure for forming a heater assembly. [Modes for carrying out the invention]

[0013] Specific examples and embodiments of aspects and features are discussed / described herein. Some aspects and features of specific examples and embodiments can be carried out conventionally and are not discussed / described in detail for the sake of brevity. Therefore, it will be understood that aspects and features of apparatus and methods discussed herein but not described in detail can be carried out according to any prior art for carrying out such aspects and features.

[0014] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating material (or its components) of the aerosol supply system is not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0015] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device, e-cigarette, or e-nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement. Throughout the following description, the term "e-cigarette" will be used from time to time, but this term may be used interchangeably with "aerosol (vapor) delivery system."

[0016] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of one or more aerosol-generating materials that can be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0017] In some embodiments, the aerosol-generating material or each aerosol-generating material may also contain one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0018] The active substances used herein may be physiologically active materials, which are materials intended to achieve or enhance a physiological response. Active substances may be selected from, for example, dietary supplements, nootropics, and psychostimulants. Active substances may be naturally occurring or obtained by synthesis. Active substances may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or their components, derivatives, or combinations thereof. Active substances may also include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant substances.

[0019] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0020] As described in the specification, the active substance may include one or more vegetable substances or their components, derivatives, or extracts, or may be derived therefrom. As used herein, the term "vegetable substance" includes, but is not limited to, any material derived from plants, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, shells, etc. Alternatively, the material may contain synthetically obtained active compounds that are naturally present in the vegetable substance. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets. Exemplary vegetable substances are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hops, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, teas such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, chrysanthemum flower, vanilla, wintergreen, perilla, turmeric, curcuma, sandalwood, silantro, bergamot, orange flower, ginkgo biloba, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, caraway, vervain, tarragon, geranium, mulberry, burdock, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: Japanese mint, Mentha canadensis L., Egyptian mint, Mentha spicata L., Mentha spicata cv., Mentha spicata cv., Spearmint, Kentucky Colonel mint, Horsemint, Pineapple mint, Pennyroyal mint, Mentha arvensis cv., and Apple mint.

[0021] In some embodiments, the active substance comprises, or is derived from, one or more vegetable substances, or constituents, derivatives or extracts thereof, and the vegetable substance is tobacco.

[0022] In some embodiments, the active substance comprises, or is derived from, one or more vegetable substances, or constituents, derivatives or extracts thereof, and the vegetable substance is selected from eucalyptus, star anise, cocoa, and hemp.

[0023] In some embodiments, the active substance comprises, or is derived from, one or more vegetable substances, or constituents, derivatives or extracts thereof, and the vegetable substance is selected from rooibos and fennel.

[0024] As used herein, the terms “flavoring” and “flavoring agent” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.These are naturally occurring flavorings, plant substances, plant substance extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, toro). Fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang Mint oil from any of the following species: sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any of the Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, maize It may contain other additives such as chollum, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant-based substances, or breath fresheners.These may be mimicry ingredients, synthetic or natural ingredients, or blends thereof. They may be in any suitable form.

[0025] In some embodiments, the flavor includes menthol, spearmint, and / or peppermint. In some embodiments, the flavor includes cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from cannabis.

[0026] In some embodiments, the flavor may include a sensory stimulant, which is intended to achieve somatosensations that are normally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the aroma or taste nerves, and these may include agents that produce heating, cooling, tingling, or numbing effects. A preferred thermal agent may be, but is not limited to, vanillyl ethyl ether, and a preferred cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0027] The aerosol-forming agent material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may contain one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetins, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0028] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0029] Aerosol modifiers are typically substances located downstream of an aerosol-generating region and are configured to modify the generated aerosol, for example, by altering the taste, flavor, acidity, or other properties of the aerosol. Aerosol modifiers may be provided within an aerosol modifier release component that is capable of selectively releasing the aerosol modifier.

[0030] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may contain, for example, one or more of the following: flavorings, colorings, water, and carbon adsorbents. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, threads, or granules. The aerosol modifier does not need to contain a filter material.

[0031] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device. In some embodiments, the disclosure relates to consumables comprising aerosol-generating materials and configured for use with a non-combustible aerosol supply device. These consumables may be referred to as articles throughout the disclosure.

[0032] In some embodiments, a non-combustible aerosol supply system, for example, a non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, a power supply.

[0033] In some embodiments, the non-combustion aerosol supply system may include a consumable receiving area, an aerosol generator, an aerosol generating area, a housing, a suction port, a filter, and / or an aerosol modifier.

[0034] In some embodiments, consumables for use with a non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a suction port, and / or an aerosol modifier.

[0035] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to supply thermal energy to the aerosol-generating material in order to release one or more volatile substances from the aerosol-generating material to form an aerosol.

[0036] According to the principles of this disclosure, a heater assembly is provided which includes one or more capillaries extending through the heater assembly from one side to the other. The function of the capillaries is to supply a liquid aerosol-generating material (or any other flowable aerosol-generating material) from a first side of the heater assembly to a second side of the heater assembly, and a heater layer (i.e., a layer configured to increase its temperature in response to the application of power) can vaporize the liquid aerosol-generating material. The substrate forming the heater assembly is provided with one or more distribution channels. The distribution channels are provided on the sides of the heater assembly, more specifically on (one or more) sides having the shortest distance between the center of that surface and the center of the heater assembly. In other words, the distance from the center of a given side to the center of the heater assembly is shorter than the distance between the center of any other side of the heater assembly and the center of the heater assembly. In the case of a rectangular parallelepiped heater assembly, these are the two surfaces having the second largest surface area. The distribution channels are configured to supply the aerosol-generating material to the capillaries passing through the heater assembly.

[0037] Therefore, an aerosol supply system encompassing a heater assembly (such as within a cartomizer of the aerosol supply system) can be configured such that one or more distribution channels on the side of the heater assembly are in direct contact with an aerosol-generating material storage section for storing the aerosol-generating material. In this way, the aerosol-generating material can be supplied to distribution channels that are typically much shorter in distance from the center to the heater assembly, supplying it to the capillaries (and then to the heater layer), thereby enabling a faster (larger, i.e., larger) supply of the aerosol-generating material to the heater layer. Furthermore, since the distribution channels for supplying the capillaries are located on the surface with the second largest surface area, more distribution channels can be provided, thereby further increasing the supply of aerosol-generating material to the heater layer. Thus, it can be seen that providing one or more distribution channels on the side of the heater assembly's substrate, exposing this side to the aerosol-generating material storage section, can help improve the performance of the heater assembly with respect to its ability to transport liquid aerosol-generating material to the heater layer.

[0038] Figure 1 schematically shows an aerosol supply system 1 according to an aspect of this disclosure. The aerosol supply system 1 comprises an aerosol supply device 2 and a consumable 3, as shown herein and referred to as a cartomizer 3. Together, the aerosol supply device 2 and the cartomizer 3 form the aerosol supply system 1.

[0039] The cartomizer 3 is configured to engage with and disengage from the aerosol supply device 2. That is, the cartomizer 3 is detachably connected to / connectable to the aerosol supply device 2. More specifically, the cartomizer 3 is configured to engage with / disengage from the aerosol supply device 2 along the longitudinal axis L1. The cartomizer 3 and the aerosol supply device 2 are provided with appropriate connectors, such as push-in connectors and threaded connectors, that enable the cartomizer 3 and the aerosol supply device 2 to engage with / disengage from each other.

[0040] The cartomizer 3 includes a reservoir for storing aerosol-generating material. Therefore, the reservoir may also be referred to as the aerosol-generating material storage section. Hereinafter, the aerosol-generating material is a liquid aerosol-generating material. The liquid aerosol-generating material (which may also be referred to herein simply as liquid, raw material, or e-liquid) may be a conventional e-liquid, which may or may not contain nicotine. However, it should be understood that other liquids and / or aerosol-generating materials may be used in accordance with the principles of this disclosure. The cartomizer 3 can be removed from the aerosol supply device 2, for example, when it is necessary to replenish the liquid or replace it with another (full) cartomizer 3.

[0041] The aerosol supply device 2 comprises a power source (such as a rechargeable battery) and control electronics. As described below, the cartomizer 3 comprises an electric heater assembly. When the cartomizer 3 is coupled to the aerosol supply device 2, the control electronics of the aerosol supply device 2 are configured to supply power to the heater assembly of the cartomizer 3 to generate an aerosol from the liquid aerosol-generating material supplied to the heater assembly. The control electronics may comprise various components for facilitating / controlling the supply of power to the cartomizer 3. For example, the control electronics may include an airflow sensor (not shown) configured to detect when a user of the aerosol supply system 1 inhales the aerosol supply system and to supply power in response to such detection, and / or a push button (not shown) that is pressed by the user and supplies power in response to such detection. Depending on the configuration of the aerosol supply device 2, additional functions may be controlled by the control electronics (for example, the control electronics may be configured to control / regulate the recharging of the power source or to facilitate wireless communication with another electronic device such as a smartphone). The features and functions of the aerosol supply device 2 are not most important to this disclosure.

[0042] Figure 2 shows an exemplary cartomizer 3 suitable for use in the aerosol supply system of Figure 1. From the exploded view of Figure 2, it can be seen that the cartomizer 3 is assembled from the stacking of components: an outer housing 4, an upper clamp unit 5, a heater assembly 6, a lower support unit 7, and an end cap 8.

[0043] The cartomizer 3 has an upper end 31 and a lower end 32 spaced apart along the longitudinal axis L1, which is the longitudinal axis of the cartomizer and the longitudinal axis of the aerosol supply system 1. The upper end 31 of the cartomizer 3 defines the mouthpiece 33 of the aerosol supply system 1 (from which a user can place their mouth and inhale). The mouthpiece 33 includes a mouthpiece opening 41 provided at the upper end 42 of the outer housing 4 in the center of the upper surface 43.

[0044] The outer housing 4 includes a circumferential side wall 44 that extends downward from the upper end 42 to the lower end 45 of the outer housing 4, defining an internal reservoir 46 for holding the liquid aerosol generating material. Before assembly of the cartomizer 3, the lower end 45 of the outer housing is open, but during assembly, the lower end 45 is closed by a plug formed by the upper clamp unit 5 and the lower support unit 7, which are stacked together with the heater assembly 6 positioned between them.

[0045] The upper clamp unit 5 is an intermediate component in the stacking of components. The upper clamp unit 5 includes a block-shaped foot 51 and an upwardly extending air tube 52. On both sides of the air tube 52, the foot 51 includes holes (wells) 53 that descend from a flat upper surface 54 of the foot 51 to a flat bottom surface (not shown in Figure 2). At the bottom surface, each hole 53 is open, specifically opening into an elongated recess formed in the bottom surface, the depth of which is approximately equal to the thickness of the heater assembly 6. The recess is provided to accommodate the heater assembly 6 when the upper clamp unit 5 engages with the lower support unit 7, but the recess is dimensioned to provide clearance around at least a portion of the heater assembly 6 when the heater assembly 6 is positioned within the recess. The foot 51 is designed to engage with the outer housing 4 (more specifically, so that the outer circumferential surface of the foot presses against the inner circumferential surface of the outer housing 4). The foot portion 51 may have an appropriate shape and may include appropriate sealing components to reduce or prevent leakage of liquid between the outer surface of the foot portion 51 and the inner surface of the housing 4.

[0046] The air tube 52 extends upward from the bottom of the hole 53 and defines an internal air passage 58. When the upper clamp unit 5 engages with the outer housing 4, the air tube 52 extends to and surrounds the suction opening 41. The outer housing 4 and / or the air tube 52 can be appropriately configured to provide a liquid-tight (and optionally airtight) seal between the two. As will be understood below, air / aerosol is intended to exit through the suction opening 41 along the air tube 52, while the space around the air tube 52 and within the outer housing 4 defines a reservoir 46 for storing liquid aerosol-generating material. Thus, it should be understood that, apart from the opening of the hole 53, the reservoir 46 is a sealed space defined by the outer housing 4, the outer surface of the air tube 52, and the foot 51.

[0047] The lower support unit 7 is block-shaped, having a substantially flat top surface 71 and a flat bottom surface 72. A central air passage 73 extends upward from the bottom surface 72 to the top surface 71. The block of the lower support unit 7 has through holes 74 on both sides of the air passage 73. In the exemplary cartomizer 3 of Figure 2, co-molded contact pads 75 in the form of pins are inserted into the through holes 74. More specifically, each contact pad 75 is press-fitted into its respective through hole 74. Each contact pad 75 provides an electrical connection path from the bottom surface 72 to each end of the heater assembly 6 when the heater assembly 6 is sandwiched between the top surface 71 of the lower support unit 7 and the recess in the bottom surface 55 of the upper clamp unit 5.

[0048] Similar to the upper clamp unit 5, the lower support unit 7 is designed to engage with the outer housing 4 (more specifically, so that the outer circumferential surface of the lower support unit 7 is pressed against the inner circumferential surface of the outer housing 4). The lower support unit 7 has an appropriate shape and may include appropriate sealing components to reduce or prevent fluid leakage between the outer surface of the lower support unit 7 and the inner surface of the housing 4. The feet 51 of the upper clamp unit 5 and the lower support unit 7 (which has a block-like shape) are joined together to form a plug that seals the lower end of the reservoir 46.

[0049] As shown in Figure 2, the cartomizer 3 includes an end cap 8 at its lower end. The end cap 8 is made of metal, and in this example, the aerosol supply device 2 is equipped with a magnet that is attracted to the metal of the end cap 8, so that it helps to hold the cartomizer 3 inside the aerosol supply device 2 when the cartomizer 3 is inserted into the upper end of the aerosol supply device 2. The end cap 8 has a bottom wall 81 with a central opening 82 (not shown in Figure 2). The end cap 8 also has a circumferential side wall 83 with two opposing notches 84, which engage on corresponding projections 49 on the outer surface of the lower end of the side wall 44 of the outer housing 4, so that the end cap 8 has a snap-fit ​​connection to the lower end of the outer housing 4. When fitted into place, the end cap 8 holds the lower support unit 7, the upper clamp unit 5, and the heater assembly 6 sandwiched between the lower support unit 7 and the upper clamp unit 5 in place.

[0050] By configuring the lower support unit 7 to form a snap-fit ​​connection with the lower end of the side wall 44 of the outer housing 4, the end cap 8 can be omitted (to reduce the number of components). Furthermore, the cartomizer 3 may have a recess that engages with a projection on the upper end 21 of the main housing 2, so as to provide a releasable connection between the cartomizer and the main housing.

[0051] In either case, the cartomizer 3 is provided with a part that connects to the main housing 2 (or aerosol generating device 2), which may be more commonly called a device connection. In the above example, the device connection may include a metal cap 8 including a bottom wall 81 and circumferential side walls 83, and / or a lower support unit 7 including a bottom surface 72. More commonly, the device connection of the cartomizer 3 may encompass any part of the cartomizer 3 that contacts, abuts, engages with, or otherwise connects to the main housing 2.

[0052] When the components of the cartomizer 3 are assembled together, there is an air passage that extends from the lower end 32 to the upper end 31 of the cartomizer 3, which is formed by air passage 73, which leads to air passage 58 and then to the intake opening 41. Where air passage 73 intersects with air passage 58, the airflow branches as it passes around the side edge of the heater assembly 6.

[0053] Referring back to Figure 1, the upper end 21 of the aerosol supply device 2 includes air inlet holes 22 on both sides of the aerosol supply device 2 (one of the two air inlet holes 22 is visible in Figure 1). Air can flow laterally inward relative to the longitudinal axis L1 so that it enters the air inlet holes 22, enters the lower end of the air passage 73 of the lower support unit 7, and begins to flow toward the suction port 33 in the direction of the longitudinal axis L1.

[0054] Figure 3a schematically shows a cross-sectional view of a portion of the cartomizer 3 in Figures 1 and 2. Specifically, Figure 3a shows a portion of the cartomizer 3 corresponding to the lower part of the cartomizer 3, where "lower" refers to the portion of the cartomizer 3 closer to the cap 8 than the mouthpiece 33. The shown cross-section is a plane cross-section extending along the longitudinal axis L1 of the cartomizer 3 and perpendicular to the longitudinal length of the heater assembly 6.

[0055] Figure 3b schematically shows a view of the cartomizer 3 along its longitudinal axis L1, facing the bottom surface 55 of the upper clamp unit 5, with the heater assembly 6 in place (note that this figure is oriented in the direction shown in Figure 3a and is labeled "B"). Specific features of the cartomizer 3 in Figures 1 and 2 have been omitted for clarity.

[0056] Figures 3a and 3b show the relative arrangement of the heater assembly 6, the upper clamp unit 5, and the lower support unit 7, in particular the positions of the hole 53 and hole opening 53a formed in the foot portion 51 of the upper clamp unit 5 relative to the end of the heater assembly 6. The heater assembly 6 is positioned in the elongated recess provided in the foot portion 51 of the upper clamp unit 5.

[0057] The heater assembly 6 is positioned such that, when the cartomizer 3 is assembled, the first surface 6a of the heater assembly 6 abuts against the upper surface 71 of the lower support unit 7. The foot 51 of the upper clamp unit 5 includes an elongated recess suitable for accommodating the heater assembly 6. The elongated recess is sized to have a depth approximately equal to the depth or thickness of the heater assembly 6, a width approximately equal to the width of the heater assembly 6, and a length approximately equal to the length of the heater assembly 6. However, as is clearly seen in Figure 3b, the elongated recess has portions where the width of the recess is greater than the width of the heater assembly 6. In particular, Figure 3b shows an elongated recess that is wider than the width of the heater assembly 6 in the region corresponding to the opening 53a (i.e., where the opening 53a overlaps the heater assembly 6). This region where the recess is wider than the width of the heater assembly 6 is shown in Figure 3b as extending toward either end of the heater assembly 6. In this way, as will be described in more detail below, at least a portion of the longer side of the heater assembly 6 (indicated by reference numeral 6c in Figure 3b) is exposed to the hole 53 and therefore to the liquid aerosol-generating material stored in the reservoir 46.

[0058] Referring to Figure 3a, the heater assembly 6 is sandwiched between the lower surface of the air pipe 52, the foot 51 of the upper clamp unit 5, and the upper surface 71 of the lower support unit 7. The lower surfaces of the air pipe 52 and the foot 51 are in contact with the second surface 6b of the heater assembly 6, which is opposite the first surface 6a of the heater assembly 6. The lower surface of the air pipe 52, together with the recess of the foot 51, forms a seal between the reservoir 46 and the air channel 58 / air channel 73. Thus, it should be understood that there is a portion of the heater assembly 6 that is in direct fluid communication with the reservoir 46 (i.e., the region of the heater assembly 6 that overlaps with the hole 53 / hole opening 53a), and a portion of the heater assembly 6 that is indirectly in fluid communication with the reservoir 46 through the ends of the heater assembly 6 (i.e., the central portion of the heater assembly 6). Therefore, the holes 53 and the opening 53a allow the liquid aerosol-generating material to come into contact with a portion of the heater assembly 6 that overlaps with the opening 53a of the holes 53. In the described embodiment, at least a portion of the second surface 6b of the heater assembly 6 can come into contact with the liquid aerosol-generating material in the reservoir 46, and due to the fact that the elongated recess is larger than the heater assembly 6 in the region overlapping with the holes 53 / opening 53a, the third (outer) surface 6c of the heater assembly 6 can also come into contact with the liquid aerosol-generating material in the reservoir 46. The third surface 6c is a surface of the heater assembly 6 provided along both sides of the heater assembly 6 and extending generally in the direction of the longitudinal axis L1 (best seen in Figure 3b). In particular, the third surface 6c is defined by the length and thickness of the heater assembly 6.

[0059] Heating of the liquid to achieve vaporization or aerosol generation is performed at least in the central portion of the heater assembly 6 so that the vaporized liquid can be carried by air passing from the air passage 73 around the central portion of the heater assembly 6 and then pass through the air passage 58.

[0060] Therefore, the heater assembly 6 is positioned within the cartomizer 3 such that multiple surfaces (or parts thereof) of the heater assembly 6 are in direct contact with the reservoir 46. It should be understood that the multiple surfaces (or parts thereof) of the heater assembly 6 are positioned to contact the liquid aerosol-generating material in the reservoir 46 only when the liquid aerosol-generating material is present in the holes 53. For example, if the cartomizer 3 is inverted during use (i.e., rotated 180° around an axis perpendicular to the longitudinal axis L1), it is likely that the air in the reservoir 46 will occupy the holes 53 instead of the liquid aerosol-generating material.

[0061] Furthermore, in some embodiments, a wicking material such as cotton or glass fiber formed as a layer can be provided between the heater assembly 6 and the upper clamp unit 5, the wicking material in contact with the hole 53, and the liquid aerosol-generating material can be transported in the longitudinal direction of the wicking material / heater assembly 6 (along the longitudinal axis of the heater assembly 6). Additionally or alternatively, in some embodiments, the heater assembly 6 may be formed from a porous substrate (such as a sintered material or ceramic).

[0062] Now, turning our attention to the heater assembly 6, we see that the heater assembly 6 is a microfluidic heater assembly. Figures 4 and 5 show the microfluidic heater assembly 6 in more detail, particularly in perspective views. Figures 4 and 5 exaggerate certain elements of the heater assembly 6 to aid in understanding its features. Figure 4 shows the microfluidic heater assembly 6 according to a first embodiment, and Figure 5 shows the microfluidic heater assembly 6 according to a second embodiment.

[0063] The microfluidic heater assembly 6 comprises a substrate 62 and an electrical resistance layer 64 disposed on the surface of the substrate 62.

[0064] In some embodiments, the substrate 62 is formed from a non-conductive material such as quartz (silicon dioxide), however, it should be understood that other suitable non-conductive materials such as ceramics may also be used. In other embodiments, the substrate may be formed from a conductive material.

[0065] The method by which the substrate 62 is formed and the materials used to fabricate it are not of most importance to the principles of this disclosure.

[0066] The electrical resistance layer 64 is formed from any suitable conductive material, such as a metal or metal alloy such as titanium or nickel-chromium. The electrical resistance layer 64 can be formed on the surface of the substrate 62 by any suitable method. For example, the electrical resistance layer 64 may be provided as a film that is bonded or otherwise attached to the surface of the substrate 62. Alternatively, the electrical resistance layer 64 may be formed by deposition techniques such as chemical deposition or vapor deposition. The method by which the electrical resistance layer 64 is formed and the materials used to make it are not of most importance to the principles of this disclosure.

[0067] In the described embodiment, the heater assembly 6 is flat, in the form of a rectangular block, and elongated in the direction of the longitudinal axis L2. The heater assembly 6 has a strip-like shape and parallel sides. The heater assembly 6 has parallel upper and lower principal faces (planes) (first face 6a and second face 6b), parallel sides (third face 6c) and parallel end faces (fourth face 6c). More specifically, the first and second faces 6a, 6b are defined by the width and length of the heater assembly 6, the third face 6c is defined by the length and thickness of the heater assembly 6, and the fourth face 6d is defined by the width and thickness of the heater assembly 6. The third and fourth faces 6c, 6d are sides of the heater assembly 6 and extend between the first and second faces 6a, 6b. The third and fourth faces 6c, 6d can more generally be defined as faces that share edges with the first and second faces 6a, 6b.

[0068] The first surface 6a, one third surface 6c, and one fourth surface 6d are shown in Figures 4 and 5. In the illustrated embodiments of Figures 4 and 5, the heater assembly 6 is 10 mm long, 1 mm wide, and 0.12 mm thick (the substrate 62 is approximately 0.10 mm thick, and the electrical resistance layer 64 is approximately 0.02 mm thick). The small size of the heater assembly 6 allows for a smaller overall size of the cartomizer 3, thereby reducing the overall mass of the cartomizer components. However, it should be understood that in other embodiments, the heater assembly 6 may have different dimensions and / or shapes depending on the actual application. For example, in some embodiments, the heater assembly 6 may be a 3 × 3 mm chip.

[0069] Along the longitudinal axis L2, the heater assembly 6 has a central section 67 and first and second ends 68, 69. In Figures 4 and 5, the length of the central section 67 (relative to the length of the ends 68, 69) is exaggerated for visual clarity. When the vaporizer is in place within the cartomizer, the central section 67 is positioned within the air passages 73 and 58. The central section 67 extends across the upper end of the air passage 73 of the lower support unit 7 and the lower end of the air passage 58 of the upper clamp unit 5. The ends 68, 69 are located between the hole 53 of the upper clamp unit 5 and the lower support unit 7.

[0070] Multiple capillaries 66 are provided in the central portion 67 of the heater assembly 6. Although only the openings of the capillaries 66 are shown (exaggerated for clarity) in Figures 4 and 5, the capillaries 66 extend from one side of the heater assembly 6 to the other. More specifically, the capillaries extend from the side of the heater assembly 6 opposite the electrical resistance layer 64 (a second surface 6b not shown in Figures 4 and 5) through the substrate 62 toward the surface of the substrate 62 where the electrical resistance layer 64 is located, and then through the electrical resistance layer 64 (first surface 6a).

[0071] Multiple capillaries 66 extend substantially linearly through the heater assembly 6 (i.e., the capillaries 66 follow substantially linear paths). Substantially, this means that the capillaries 66 follow paths within 5%, 2%, or 1% of a straight line. This measure can be obtained in any suitable way, for example, by comparing the length of the distance from a first point to a second point along the length of the capillary 66 with the corresponding distance the central axis of the capillary 66 extends between the same two points. The capillaries 66 are formed in the heater assembly 66 by a manufacturing process. That is, the capillaries 66 do not exist naturally in the substrate material 62 or the electrical resistance layer 64; rather, the capillaries 66 are formed in the substrate material 62 and the electrical resistance layer 64 by a suitable process. A suitable process for forming the capillaries 66 is laser drilling, especially when forming capillaries that follow substantially linear paths. However, any other suitable technique may be used to generate the capillaries 66.

[0072] The capillary tube 66 is configured to transport liquid from one side of the heater assembly 6 (i.e., the second side 6b) to the electrical resistance layer 64. The exact dimensions of the capillary tube 66, particularly its diameter, may be set according to the liquid stored in the reservoir 46 of the cartomizer 3 and subsequently used with the heater assembly 6. For example, the properties (e.g., viscosity) of the liquid aerosol-generating material in the reservoir 46 of the cartomizer 3 can determine the diameter of the capillary tube 66 to ensure that an appropriate flow of liquid is supplied to the electrical resistance layer 64. However, in some embodiments, the capillary tube 66 may have a diameter of several tens of microns, e.g., 10 μm to 250 μm, 10 μm to 150 μm, or 10 μm to 100 μm. However, it should be understood that in other embodiments, the capillary tube 66 may be set differently based on the properties of the liquid being vaporized and / or the desired supply of liquid to the electrical resistance layer 64. Furthermore, it should be understood that, in order to achieve the desired level of flow to the electrical resistance layer 64, not only the diameter of the capillaries 66 but also the number of capillaries 66 per unit area can affect the supply of liquid to the electrical resistance layer 64.

[0073] Figure 4 shows a first embodiment of the heater assembly 6, which includes a substrate 62 formed from or containing a porous material. The porous substrate 62 can be formed from a naturally porous material such as sponge, porous stone, or ceramic, or from a material that has been fabricated to be porous, such as sintered metal or other material. These materials, whether naturally formed or fabricated, have pores or hollow regions that are interconnected and define pathways that follow substantially random paths through the material. In particular, in Figure 4, the substrate 62 is formed from sintered quartz (silicon dioxide).

[0074] The interconnected pores or voids in the porous substrate 62 result in one or more distribution channels (represented by reference numeral 62a in Figure 4). More specifically, the interconnected pores or voids in the porous substrate 62 result in one or more naturally formed distribution channels 62a, in that these distribution channels 62a are either naturally present (e.g., in porous ceramics) or naturally present as a result of the formation of the substrate (e.g., sintered quartz). One or more distribution channels 62a extend from the surface of the substrate 62 (e.g., the second surface 6b, the third surface 6c, or the fourth surface 6d) through the substrate 62, following substantially random paths. The presence of capillaries 66 formed in the porous substrate 62 (e.g., by machining or drilling) means that at least some of the random paths resulting from the interconnected pores or voids intersect with the capillaries 66. Therefore, any liquid aerosol-generating material in interconnected pores or voids that can move along a path intersecting the capillary 66 can be supplied to the capillary 66 and subsequently to the electrical resistance layer 64 via the capillary 66. Thus, the naturally formed distribution channel 62a can supply the liquid aerosol-generating material to the capillary 66, thereby assisting the wicking performance of the capillary 66 and the heater assembly 6.

[0075] Figure 5 shows a second embodiment of the heater assembly 6, which includes a substrate 62 formed from a substantially impermeable or opaque material. Unlike the embodiment in Figure 4, the substantially impermeable substrate 62 is formed from a material that does not allow liquids (particularly liquid aerosol-generating materials) to flow through the substrate. It should be understood that this relates only to the material from which the substrate 62 is made. For example, the presence of capillaries 66 allows liquid aerosol-generating materials to flow from one side of the substrate 62 to the other, but for the material forming the substrate 62, liquid aerosol-generating materials cannot flow into or through the material itself. An impermeable substrate 62 can be provided using any suitable material, for example, bulk quartz (silicon dioxide) can be used.

[0076] In the embodiment shown in Figure 5, the substrate 62 is provided with one or more distribution channels 62a. In this embodiment, the distribution channels 62b are artificially formed (or fabricated) distribution channels. That is, the distribution channels 62b are formed by engineering processes such as drilling, machining, or etching to form the distribution channels 62b. In some embodiments, the distribution channels 62b can be formed by the same process as forming the capillaries 66, for example, by laser drilling. As seen in Figure 5, the distribution channels 62b extend into the substrate 62 from an opening on the side (particularly the longitudinal side 6c). The distribution channels may extend through the entire width of the substrate 62, or through only a portion of the width of the substrate 62. In either case, the distribution channels 62b are formed to block at least one capillary 66. That is, similar to the embodiment in Figure 4, any liquid aerosol-generating material in the distribution channel 62b (e.g., entering through an opening in the third surface 6c of the heater assembly 6) can move along a path intersecting the capillary 66, and thus be supplied to the capillary 66, and subsequently supplied to the electrical resistance layer 64 via the capillary 66. Thus, the artificially formed (fabricated) distribution channel 62b can supply the liquid aerosol-generating material to the capillary 66, thereby assisting the wicking performance of the capillary 66 and the heater assembly 6. However, in the example in Figure 5, the distribution channel 62b is formed to extend along a predetermined path, as opposed to the more random paths resulting from interconnected pores or voids.

[0077] However, it should be understood that combinations of the methods described in the first and second embodiments of Figures 4 and 5, respectively, may also be provided. That is, in some embodiments, the porous substrate 62 of the first embodiment may be provided with the artificially formed distribution channels 62b of the second embodiment. In such embodiments, at least some of the random paths resulting from the interconnected pores or voids may, additionally or alternatively, intersect with the artificially formed distribution channels 62a, thereby supplying the liquid aerosol-generating material to the capillaries 66.

[0078] Regardless of how the distribution channels 62a and 62b are provided, they are configured to allow the flow of liquid aerosol-generating material along them. For example, the average pore size and / or properties of the substrate 62 may be selected to facilitate the liquid along random paths formed by interconnected pores. Alternatively, the size and shape (e.g., cross-section) of the distribution channels 62b may be selected to facilitate the liquid along predetermined paths formed by the distribution channels 62b. However, it should be understood that the properties of the liquid aerosol-generating material used with the heater assembly 6 may determine the actual size, dimensions, etc., of the distribution channels 62a and 62b.

[0079] According to the principle of this disclosure, one or more distribution channels 62a, 62b are provided extending from the third outer surface 6c of the heater assembly 6. The one or more distribution channels 62a, 62b extend from the third outer surface 6c of the heater assembly 6 to at least a position within the substrate 62, thereby enabling the liquid aerosol generating material to be supplied to the capillary tube 66 via the one or more distribution channels 62a, 62b.

[0080] In particular, one or more distribution channels 62a, 62b are provided with an inlet or opening located on the third outer surface 6c of the heater assembly 6, where the distance from the center of the third outer surface 6c to the center of the heater assembly 6 is shorter than the distance between the center of any other side of the heater assembly 6 (e.g., the fourth outer surface 6d) and the center of the heater assembly 6.

[0081] Figure 6 shows a top view of the substrate 62 of the heater assembly 6. Figure 6 is presented for illustrative purposes only, and it should be understood that the substrate 62 may be either the substrate 62 of Figure 4 or Figure 5. Figure 6 shows the substrate 62 including the edges 68, 69 and the central portion 67 (including the capillary 66 mentioned above). Furthermore, the third surface 6c and the fourth surface 6d are also shown.

[0082] Figure 6 also shows two distances d1 and d2. Distance d1 is the distance between the center of the third surface 6c and the center of the heater assembly 6 (in a plane parallel to the first surface 6a or the second surface 6b), and distance d2 is the distance between the center of the fourth surface 6d and the center of the heater assembly 6 (in a plane parallel to the first surface 6a or the second surface 6b). As can be understood, distance d2 is greater than distance d1. Therefore, if distribution channels 62a and 62b are provided, the distribution channels 62a and 62b provided extending from the third surface 6c of the heater assembly 6 extend a shorter distance to the center of the heater assembly 6 (i.e., where the capillary tube 66 is provided) than the distribution channels 62a and 62b provided extending from the fourth surface 6d of the heater assembly 6. Therefore, broadly speaking, the distribution channels 62a and 62b, which are provided to extend from the third surface 6c, can enable the liquid aerosol-generating material to be rapidly supplied to the capillary tube 66 by the fact that one or more distribution channels extend a shorter distance to the capillary tube 66.

[0083] It should be understood that the distances d1 and d2 in Figure 6 do not necessarily represent the distance over which one or more distribution channels 62a, 62b extend. For example, referring particularly to Figure 3b, the hole 53 / hole opening 53a is generally located in a region of the heater assembly 6 that may extend beyond the central portion 67 containing the capillary tube 66 (i.e., the hole 53 / hole opening 53a does not overlap with the central region 67 of the heater assembly 6). For example, the central portion 67 may be located within the air passage 58. Thus, one or more distribution channels 62a, 62b may instead be located to extend from a suitable region of the third surface 6c (i.e., corresponding to the hole 53 / hole opening 53a) along an oblique path to the central portion 67, or to extend by, for example, an L-shaped path (it should be understood that naturally formed distribution channels may then follow an approximation of an oblique or L-shaped path). However, in such cases, the distance over which such distribution channels extend is generally smaller than, or at least equal to, the distance over which distribution channels extend from the fourth surface 6d to the central portion 67.

[0084] Furthermore, it should be understood that the configuration of the cartomizer 3 housing the heater assembly 6 in the illustrated orientation is presented as an exemplary configuration of such a cartomizer 3 incorporating the heater assembly 6. The principles of this disclosure also apply to other configurations of the cartomizer 3 (e.g., configurations with components similar or different to those shown in Figures 1 and 2, and layouts similar or different to those shown in Figure 2). Broadly speaking, the cartomizer is likely to have an upper end (having an intake opening 41) and a lower end. In the above example, the heater assembly 6 is positioned below the reservoir 46, substantially horizontal with respect to the longitudinal axis of the cartomizer 3, and within an airflow path substantially perpendicular to the longitudinal axis of the heater assembly. However, this is not required, and in other embodiments, the cartomizer 3 may be configured differently depending on the actual specific design and application. For example, the heater assembly 6 may be positioned such that the airflow is substantially parallel to the longitudinal axis of the heater assembly along, for example, the exposed surface of the electrical resistance layer 64. For example, the upper clamp unit 5 may not have a central air passage 58, but instead an air passage may be provided on one side of the upper clamp unit 5. Air can enter the cartomizer 3 through a suitable inlet, flow along the longitudinal surface of the heater assembly 6 (and along the electrical resistance layer 64), and then pass substantially vertically through the air passage 58 located at one end of the upper clamp unit 5 (e.g., the end opposite the air inlet). The outer housing 4 and the intake opening 41 can be appropriately configured. In such an example, the entire second surface 6b of the heater assembly may be exposed to the reservoir 46. In such an embodiment, the capillary 66 may be located not only within the central portion 67 of the heater assembly 6 but also across the heater assembly 6 (provided that the electrical resistance layer 64 can be coupled to the power supply).

[0085] Figures 7a and 7b provide a very schematic illustration of such an example of the cartomizer 3. Figure 7a shows a cross-sectional view of the cartomizer 3, in particular of the heater assembly 6' positioned between the upper clamp unit 5' and the lower support unit 7', while Figure 7b shows a perspective view of the heater assembly 6' positioned in the recess of the lower clamp unit 7'. Specific other features of the cartomizer 3 are not shown for clarity. Broadly speaking, the heater assembly 6', the upper clamp unit 5', and the lower support unit 7' are configured similarly to their correspondings described with respect to Figures 1-6, differing only in their physical arrangement, as described below.

[0086] In Figure 7a, the heater assembly 6' is shown positioned between the lower support unit 7' and the upper clamp unit 5'. In this example, the lower clamp unit 7' includes an elongated recess provided for accommodating the heater assembly 6' (however, the elongated recess could instead be provided in the upper clamp unit 5'). When clamped together, the upper clamp unit 5' provides a liquid-tight seal with the upper surface of the lower clamp unit 7' and / or the heater assembly 6' (in much the same manner as described above with respect to Figures 1 to 6). Above the heater assembly 6' is a reservoir 46' that holds the liquid aerosol-generating material.

[0087] During use, air can enter the cartomizer through the air inlet 7a', schematically shown as passing through the side wall of the lower clamp unit 7' in Figure 7a. The air flows into an air passage 73', which is directed to pass through the heater assembly 6' (particularly the surface including the electrical resistance layer 64), before passing through the air outlet 5a', schematically shown as passing through the side walls of the lower support unit 7' and the upper clamp unit 5'. The airflow is represented by the arrows in Figure 7a. It should be understood that the outer housing 4 of the cartomizer 3 may be appropriately fitted to receive the airflow from the air outlet 5a', for example, the air tube 52 may be appropriately fitted to guide the airflow to the intake opening 41. Furthermore, it should be understood that, unlike the arrangements in Figures 1 to 6, the airflow in this example does not branch around the surface of the heater assembly, but instead is in a direction substantially parallel to the surface of the heater assembly 6'. Unlike the heater assemblies in Figures 1 to 6, heater assembly 6' may have capillaries extending substantially throughout the heater assembly 6' (for example, in the region exposed to reservoir 46').

[0088] Figure 7b shows in more detail the arrangement of the heater assembly 6' relative to the lower support unit 7'. In particular, note that the heater assembly 6' is positioned in an elongated recess as described above, but the elongated recess is wider than the heater assembly 6'. Therefore, the holes 53' and hole openings 53a' are formed in the lower support unit 7' on both sides of the heater assembly 6'. More specifically, it can be seen that the third outer surface 6c' of the heater assembly 6' remains exposed and is in direct fluid communication with the holes 53' / hole openings 53a'. Compared to the arrangements in Figures 1 to 6, and especially referring to Figure 3b, the entire third outer surface 6c' of the heater assembly 6' is exposed and is in direct fluid communication with the holes 53' and 53a'.

[0089] Therefore, it should be understood that, similar to the arrangements in Figures 1 to 6, the liquid aerosol-generating material from the reservoir 46' can enter the heater assembly 6' through the second surface of the heater assembly 6' (the largest surface shown in Figure 7b), through either the interconnected pores or voids if the capillaries 66 and / or the substrate 62 are formed from a porous material, and through either the distribution channels 62a and / or 62b, through the third surface 6c' of the heater assembly 6'.

[0090] Both arrangements of heater assemblies 6 and 6' in Figures 1-6 and 7a-7b are positioned such that at least a portion of the third surfaces 6c, 6c' is exposed to the reservoirs 46, 46', respectively. Configuring heater assemblies 6, 6' so that any side (6c, 6c', or 6d) is exposed to the reservoirs 46, 46' allows more liquid aerosol-generating material to enter heater assemblies 6, 6' (through the exposed surfaces), thereby increasing the wetting of heater assemblies 6, 6'. Furthermore, configuring heater assemblies 6, 6' so that the third surface 6c, 6c' is exposed to the reservoirs 46, 46' (as opposed to the fourth surface 6d) allows for faster liquid uptake / wetting of heater assemblies 6, 6' because the distance the liquid aerosol-generating material must travel to reach the center of heater assemblies 6, 6' is relatively short (as described with respect to Figure 6). Furthermore, since the third surfaces 6c, 6c' are substantially larger by definition than the fourth surface 6d of the heater assemblies 6, 6', a larger surface area is exposed to the reservoirs 46, 46', and therefore a larger surface area is available for the liquid to enter the heater assemblies 6, 6'.

[0091] Therefore, by configuring the heater assemblies 6, 6' to have one or more distribution channels 62a, 62b extending from the third outer surfaces 6c, 6c' of the heater assemblies 6, 6' (where the third outer surface is a side of the heater assembly that shares an edge with at least one of the first outer surface 6a and the second outer surface 6b, and the third outer surfaces 6c, 6c' are defined as surfaces where the distance from the center of the third outer surface 6c, 6c' to the center of the heater assembly 6, 6' is shorter than the distance from the center of any other side of the heater assembly 6, 6' to the center of the heater assembly 6, 6'), a potential improvement in the ability of the heater assemblies 6, 6' to take in (absorb) liquid, also known as wetting, becomes possible. Not only can wetting be improved with respect to the amount of liquid that the heater assemblies 6, 6' can absorb and subsequently transfer to the electrical resistance layer 64, but the wetting rate can also be improved (i.e., the time required for the transition from a dry heater assembly 6, 6' to a wet heater assembly 6, 6' can be reduced). It should be understood that improvements in wicking and wetting can also lead to improvements in the aerosols subsequently generated using heater assemblies 6, 6', for example, the amount of aerosols generated or the consistency of aerosol generation. According to the example defined above, heater assemblies 6, 6' are provided as structures having a rectangular parallelepiped shape. The first outer surface 6a and the second outer surface 6b are the rectangular parallelepiped faces with the largest surface area (i.e., the largest faces of heater assembly 6, 6'). If heater assembly 6, 6' has a rectangular parallelepiped shape, the third outer surface 6c, 6c' are the two surfaces (one or both) with the second largest surface area. Thus, the fourth outer surface 6d is the two surfaces (one or both) with the smallest surface area. In this regard, it should be understood that surface area in this context refers to the area defined by the perimeter of each surface (as opposed to surface area which may include bumps, grooves or pores, etc.).

[0092] However, it should be understood that this disclosure is not limited to heater assemblies having a rectangular parallelepiped shape. The heater assembly can take any suitable three-dimensional shape including at least a first, second, and side outer surface. In such embodiments, the advantages of this disclosure can still be realized if the third outer surface includes one or more distribution channels and is exposed to the reservoir (in which case the distance from the center of the third outer surface to the center of the heater assembly is shorter than the distance from the center of any other side of the heater assembly to the center of the heater assembly).

[0093] Furthermore, it should be understood that the heater assembly may also have one or more distribution channels on surfaces other than the third outer surface. For example, the heater assemblies 6, 6' may also include one or more distribution channels extending from the fourth surface 6d, in addition to the channels extending from the third surfaces 6c, 6c'.

[0094] Broadly speaking, according to this disclosure, one or more distribution channels 62a, 62b extend from openings in the third outer surfaces 6c, 6c' toward the longitudinal axis L2 of the heater assembly 6, 6'. This is partly due to the fact that, in the example of a rectangular heater assembly, the third outer surfaces 6c, 6c' extend parallel to the longitudinal axis L2. However, even if the heater assembly is not rectangular, sides extending substantially parallel (but not substantially perpendicular) to the longitudinal axis may provide a shorter distance to the electrical resistance layer 64. Furthermore, in some embodiments, one or more distribution channels 62a, 62b extend perpendicular to the longitudinal axis L2 of the heater assembly. In some embodiments, one or more distribution channels 62a, 62b extend substantially toward the center of the heater assembly 6, 6'. This may be along a two-dimensional plane relative to the heater assembly (in other words, in the case of a three-dimensional structure, the center lies on an axis passing through each of the two-dimensional planes). Alternatively, the center may be the center of a point within the center of the heater assembly.

[0095] As described above, one or more distribution channels 62b can be formed by engineering processes (such as drilling or machining). In such cases, one or more distribution channels 62b follow a predetermined path formed in the substrate by the engineering process. In some embodiments, one or more distribution channels 62b follow a (substantially) linear path. This may be the case, in particular, when one or more distribution channels 62b are formed by engineering processes, for example, by drilling in bulk material, simply due to physical limitations of the engineering process. However, even when one or more distribution channels 62b are formed by engineering processes, it may be possible to form the channels non-linearly. For example, distribution channels can be formed by etching patterns onto the surfaces of two substrates (or two halves of a substrate) and then joining or touching the two substrates together, thereby aligning the etched patterns on the substrate surfaces to form distribution channels. In this way, more complex patterns and distribution channels 62b that do not necessarily follow a linear path are achievable.

[0096] Additionally or alternatively, one or more distribution channels 62a may follow random paths formed in the substrate 62 by a series of interconnected pores (for example, if the substrate 62 is formed from a porous material). In some embodiments, the porous substrate 62 can be modified by treatment or other means to remove or increase some of the interconnected voids (forming the distribution channels). For example, the fourth surface 6d of the heater assembly can be sealed by, for example, applying a coating or the like to the fourth surface 6d to seal the pores near the surface 6d.

[0097] According to the principles of this disclosure, the heater assemblies 6, 6' described above may be provided in the cartomizer 3 (or more generally in the aerosol supply system 1). The heater assemblies 6, 6' are positioned relative to the reservoir 46 (or more generally in the aerosol-generating material storage unit) such that aerosol-generating material can be supplied to the third outer surfaces 6c, 6c' of the heater assemblies 6, 6'. In some embodiments, the reservoir 46 includes one or more holes 53, the one or more holes 53 configured to allow aerosol-generating material to be supplied to at least one region of the heater assemblies 6, 6', and the heater assemblies 6, 6' are positioned such that the third outer surface is in direct fluid communication with the one or more holes 53.

[0098] The heater assemblies 6, 6' described above are generally provided as relatively small components with a relatively small footprint (compared to more conventional heater assemblies such as wicks and coils). However, partly due to the fact that the capillaries 66 are formed within the heater assemblies 6, 6' by a manufacturing process (i.e., the capillaries are fabricated, for example, by a laser drilling process), and distribution channels are provided to the heater assembly 6, the heater assembly 6 can, despite its relatively small size, yield similar, if not improved, liquid delivery and / or aerosol formation characteristics. By providing smaller components, material waste (e.g., when the cartomizer 3 is discarded) can be reduced.

[0099] In the example shown in Figure 2, the contact pad 75 directly contacts the electrical resistance layer 64 of the heater assembly 6. However, the cartomizer 3 may be provided with any suitable configuration to facilitate electrical contact between the aerosol supply device 2 and the heater assembly 6. For example, in some embodiments, electrical wiring or other conductive elements may extend between the electrical resistance layer 64 and the contact pad 75 of the cartomizer 3. This may be particularly true if the heater assembly 6 has a maximum dimension (e.g., its length) that is smaller than the minimum distance between the contact pads 75. The distance between the contact pads 75 may be determined by the electrical contact on the aerosol supply device 2.

[0100] Although the above describes a cartomizer 3 including a heater assembly 6, it should be understood that in some embodiments, the heater assembly 6 may be provided on the aerosol supply device 2 itself. For example, the aerosol supply device 2 may include a heater assembly 6 and a removable cartridge (including a reservoir of liquid aerosol generating material). The heater assembly 6 is provided to be in fluid contact with the liquid in the cartridge (e.g., by a suitable wicking element or by another fluid transport mechanism). Alternatively, the aerosol supply device 2 may include, in addition to the heater assembly 6, an integrated liquid storage area which may be refillable with liquid. More broadly, an aerosol supply system (including a separable aerosol supply device and cartomizer / cartridge, or an integrated aerosol supply device and cartridge) includes a heater assembly.

[0101] Furthermore, the above describes a heater assembly 6 in which an electrical resistance layer 64 is provided on the surface of each substrate. In the aerosol supply system 1 of Figure 2, power is supplied to the electrical resistance layer 64 via a contact pad 75. Thus, current can flow through the electrical resistance layer 64 from one end to the other to cause heating of the electrical resistance layer 64. However, it should be understood that the power for the purpose of heating the electrical resistance layer 64 may be supplied by alternative means, in particular by induction. In such embodiments, the aerosol supply system 1 comprises a coil (known as a drive coil) to which an alternating current is applied. This subsequently generates an alternating magnetic field. When the electrical resistance layer 64 is exposed to an alternating magnetic field (and if it is of sufficient strength), the alternating magnetic field generates current (eddy currents) in the electrical resistance layer 64. These currents can cause Joule heating of the electrical resistance layer 64 due to the electrical resistance of this layer 64. Depending on the material on which the electrical resistance layer 64 is formed, heating may be further induced by magnetic hysteresis (if the material is ferromagnetic or ferrimagnetic). More generally, the electrical resistance layer 64 is an example of a heater layer in a heater assembly 6 configured to generate heat when energy (e.g., electrical energy) is supplied, which can be supplied, for example, by direct contact or induction. Further methods for generating heat in the heater layer are also considered to be within the scope of the principles of this disclosure.

[0102] Furthermore, it should be understood that in some embodiments, one or more additional layers, for example, serving as protective layers, may be placed on top of the electrical resistance layer 64. In such embodiments, the capillary 66 still extends to the openings of the electrical resistance layer 64, but can extend further through the additional layers. More broadly, the capillary 66 extends through the heater assembly 6 to the openings on the sides of the heater assembly 6 containing the electrical resistance layer 64, including the openings of the electrical resistance layer 64 itself, as well as the openings of any additional layers placed above the electrical resistance layer 64.

[0103] Figure 8 shows an exemplary method for manufacturing heater assemblies 6, 6'.

[0104] The method begins in step S1 by providing a substrate 62. The method by which the substrate 62 is formed is not important to the principles of the present disclosure. For example, the substrate 62 may be cut from a portion of cultured quartz, or it may be formed by a sintering process, for example, by sintering quartz powder / fibers.

[0105] The method then proceeds to step S2, which provides one or more distribution channels 62a, 62b. In some embodiments, one or more distribution channels 62a may be formed naturally within the substrate 62, i.e., as a result of forming the substrate 62 in a certain way (e.g., forming the substrate 62 from a natural porous material or by sintering). In such embodiments, step S2 may be performed essentially in step S1. In other embodiments, one or more distribution channels 62b may be formed by engineering processes, such as laser drilling. In such embodiments, step S2 follows step S1.

[0106] According to the described embodiment, when one or more distribution channels 62a, 62b are formed in the substrate 62, the method proceeds to step S3, in which an electrical resistance layer 64 is provided on the surface of the substrate 62. The method by which the electrical resistance layer 64 is formed on the surface of the substrate 62 is not important to the principles of the present disclosure. For example, the electrical resistance layer 64 may be a sheet of metal (e.g., titanium) bonded, welded, etc., to the substrate 62. Alternatively, the electrical resistance layer 64 may be formed by vapor deposition or chemical deposition techniques using the substrate 62 as a base.

[0107] Alternatively, it should be understood that step S2 may be performed after the electrical resistance layer 64 has been deposited on the substrate 62 in step S3. It should also be understood that step S3 may be performed before step S1 (and step S2). For example, a further alternative is to grow or culture the substrate 62 using the electrical resistance layer 64 as a base. Subsequent processing steps such as step S2 may be performed afterward.

[0108] In the example described, after step S3, the method proceeds to step S4. In step S4, one or more capillaries 66 are formed within the substrate 62 / electrical resistance layer 64. As described above, the capillaries 66 extend from the surface (surface 6b) of the substrate 62 / heater assembly 6 through the electrical resistance layer 64 provided on the first surface of the substrate 62. That is, the capillaries 66 extend through the heater assembly 6. The capillaries 66 can be formed by laser drilling as described above, or by any other suitable technique. The capillaries 66 may be formed to align with one or more distribution channels 62a, 62b formed in the substrate 62 such that the capillaries 66 are in essentially fluid communication with one or more distribution channels 62a, 62b as described above (this may be especially true if one or more distribution channels 62b are fabricated).

[0109] It should be understood that step S4 may be performed before steps S2 and S3 (similarly, step S4 may follow step S1, in which case step S3 may be performed before step S1). That is, the capillary tubes 66 may be formed in the substrate 62 before forming the distribution channels 62a, 62b and / or before adding the electrical resistance layer 64.

[0110] In general, the method shown in Figure 8 is illustrative only, and any modifications to the steps or order of the steps in this method are considered within this disclosure, as described above.

[0111] After step S4, the heater assembly 6 may be formed and subsequently assembled to form the cartomizer 3 (or more generally, the heater assembly 6 may be placed within the aerosol supply system 1).

[0112] A heater assembly for an aerosol supply system is described herein, defining a three-dimensional object having multiple outer surfaces. The heater assembly includes a substrate, a heater layer configured to generate heat when energy is supplied, the heater layer provided on the substrate at a first outer surface of the heater assembly, one or more capillaries extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, the one or more capillaries for supplying aerosol-generating material to the heater layer for vaporization, the second outer surface being substantially opposite to the first outer surface, and one or more distribution channels extending from a third outer surface of the substrate to at least one capillary for supplying aerosol-generating material to the one or more capillaries. The third outer surface is a side surface of the heater assembly, the side surface sharing an edge with at least one of the first and second outer surfaces, the distance from the center of the third outer surface to the center of the heater assembly is shorter than the distance from the center of any other side surface of the heater assembly to the center of the heater assembly. Methods for manufacturing aerosol supply systems and heater assemblies are also described.

[0113] While the embodiments described above focus in some respects on several specific exemplary aerosol supply systems, it will be understood that the same principles can be applied to aerosol supply systems using other techniques. That is, the specific ways in which various embodiments of aerosol supply systems function are not directly related to the underlying principles of the examples described herein.

[0114] To address a variety of problems and to advance the technology, this disclosure illustrates various embodiments in which one or more claimed inventions may be carried out. The advantages and features of this disclosure are merely representative samples of embodiments and are not exhaustive and / or exclusive. They are presented solely to aid understanding and to teach the claimed inventions. The advantages, embodiments, examples, functions, features, structures, and / or other aspects of this disclosure should not be considered limitations to the disclosure as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claims. Various embodiments may appropriately include, be, or essentially include various combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein, and it should be understood that the features of dependent claims may be combined with the features of independent claims in combinations other than those expressly described in the claims. This disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A heater assembly for an aerosol supply system, wherein the heater assembly defines a three-dimensional object having a plurality of outer surfaces, and the heater assembly substrate, A heater layer configured to generate heat when energy is supplied, the heater layer provided on the substrate on the first outer surface of the heater assembly, One or more capillaries extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, wherein the one or more capillaries are for supplying an aerosol-generating material to the heater layer for vaporization, and the second outer surface is substantially opposite to the first outer surface, and To supply the aerosol generating material to one or more capillaries, the substrate comprises one or more distribution channels extending from the third outer surface to at least one capillary, The third outer surface is a side surface of the heater assembly, and the side surface shares an edge with at least one of the first outer surface and the second outer surface. A heater assembly in which the distance from the center of the third outer surface to the center of the heater assembly is shorter than the distance from the center of any other side of the heater assembly to the center of the heater assembly.

2. The heater assembly according to claim 1, wherein the heater assembly defines a rectangular parallelepiped, the first outer surface and the second outer surface are the surfaces of the rectangular parallelepiped having the largest surface area, and the third outer surface is one or both of the two surfaces having the second largest surface area.

3. The heater assembly according to claim 1 or 2, wherein one or more distribution channels extend from the opening on the third outer surface toward the longitudinal axis of the heater assembly.

4. The heater assembly according to any one of claims 1 to 3, wherein one or more distribution channels extend in a direction perpendicular to the longitudinal axis of the heater assembly.

5. The heater assembly according to any one of claims 1 to 4, wherein one or more distribution channels extend substantially toward the center of the heater assembly.

6. The heater assembly according to any one of claims 1 to 5, wherein one or more distribution channels follow a predetermined path formed in the substrate by engineering processing.

7. The heater assembly according to any one of claims 1 to 6, wherein one or more distribution channels follow a substantially linear path.

8. The heater assembly according to any one of claims 1 to 5, wherein one or more distribution channels follow random paths formed in the substrate by a series of interconnected pores.

9. An aerosol supply system comprising the heater assembly described in any one of claims 1 to 8 and an aerosol generating material storage section for storing an aerosol generating material, wherein the heater assembly is positioned relative to the aerosol generating material storage section so that the aerosol generating material can be supplied to the third outer surface.

10. The aerosol supply system according to claim 9, wherein the aerosol generating material storage section includes one or more holes, the one or more holes are configured to allow the aerosol generating material to be supplied to at least one region of the heater assembly, and the heater assembly is arranged such that the third outer surface is in direct fluid communication with the one or more holes.

11. A method for manufacturing a heater assembly for an aerosol supply system, wherein the heater assembly defines a three-dimensional object having a plurality of outer surfaces, and the method The steps include providing a substrate and A step of providing a heater layer on the substrate on the first outer surface of the heater assembly, wherein the heater layer is configured to generate heat when energy is supplied to it. A step of providing one or more capillaries extending from a second outer surface of the heater assembly through the heater layer provided on the first outer surface of the heater assembly, wherein the one or more capillaries are for supplying an aerosol-generating material to the heater layer for vaporization, and the second outer surface is substantially opposite to the first outer surface; The step of providing one or more distribution channels extending from the third outer surface of the substrate to at least one capillary in order to supply the aerosol generating material to one or more capillaries, The third outer surface is a side surface of the heater assembly, and the side surface shares an edge with at least one of the first outer surface and the second outer surface. A method wherein the distance from the center of the third outer surface to the center of the heater assembly is shorter than the distance from the center of any other side of the heater assembly to the center of the heater assembly.

12. A heater means for an aerosol supply system, wherein the heater means defines a three-dimensional object having a plurality of outer surfaces, and the heater means substrate, A heater layer means configured to generate heat when energy is supplied, wherein the heater layer means is provided on the substrate on the first outer surface of the heater means, A capillary means extending from a second outer surface of the heater means through a heater layer means provided on the first outer surface of the heater means, wherein the capillary means is for supplying an aerosol generating material to the heater layer means for vaporization, and the second outer surface is substantially opposite to the first outer surface, and To supply the aerosol generating material to the capillary means, the substrate is provided with a distribution means extending from the third outer surface to the capillary means, The third outer surface is a side surface of the heater means, and the side surface shares an edge with at least one of the first outer surface and the second outer surface. A heater means wherein the distance from the center of the third outer surface to the center of the heater means is shorter than the distance from the center of any other side of the heater means to the center of the heater means.

Images