Cartridge for aerosol generation system with improved sealing element

Abstract

A cartridge (100, 10) for an aerosol generation system is provided, comprising: a cartridge body (104) having a liquid storage portion (108) for holding a liquid aerosol forming substrate; a heater assembly (10, 112) having a heating element (116) for vaporizing the liquid aerosol forming substrate and a porous ceramic body (118) for transporting the liquid aerosol forming substrate from the liquid storage portion (108) to the heating element (116); and a sealing element (300) configured to provide a sealing engagement between the porous ceramic body (118) and the cartridge body (104). The sealing element (300) comprises one of a) cotton or polyethylene (PE), b) thermoplastic elastomer (TPE), and c) silicone-free rubber.

Description

Technical Field

[0001] The present invention relates to a cartridge for an aerosol generating system. The present invention also relates to an aerosol generating system comprising a cartridge.

Background Art

[0002] Aerosol generating systems that heat a liquid aerosol-forming substrate to generate an aerosol to be delivered to a user are generally known in the prior art. These systems typically comprise an aerosol generating device and a replaceable cartridge. The cartridge contains a liquid aerosol-forming substrate that can release a volatile compound when heated.

[0003] The cartridge typically also includes a heater for heating the liquid aerosol-forming substrate. In known aerosol generating systems, the heater comprises a resistive heating element wound around a wick that supplies the liquid aerosol-forming substrate to the heating element. The aerosol generating device or the cartridge also comprises a mouthpiece. When a negative pressure is applied to the mouthpiece, an electric current flows through the heating element, heating the heating element by resistive heating or Joule heating, and as a result, heating the liquid aerosol-forming substrate supplied by the wick. Thereby, a volatile compound is released from the liquid aerosol-forming substrate, cooled to form an aerosol. The aerosol is then inhaled into the user's mouth through the mouthpiece.

[0004] These aerosol generating cartridges have been found to have several drawbacks. One of them is "dry heating" or "dry puffing," which occurs when the heating element is heated while an insufficient amount of liquid aerosol-forming substrate is supplied to it. This can occur, for example, when the user consumes all the liquid aerosol-forming substrate in the cartridge and the cartridge becomes depleted and needs to be replaced. During operation, it is preferable to maintain a supply of liquid aerosol-forming substrate to the heating element so that the heating element remains moist, in order to help ensure that a satisfactory aerosol is generated when the user inhales. Dry heating can lead to overheating of the heating element and potentially to thermal decomposition of the liquid aerosol-forming substrate, which may result in undesirable byproducts and, furthermore, unsatisfactory aerosol generation. Allowing the aerosol generating system to continue operating when no liquid aerosol-forming substrate is supplied to the heating element can degrade the quality of the user experience.

[0005] In attempts to address these problems, alternative cartridges have been proposed that include a heater assembly having a resistance heating element located on the heated surface of a porous material. In particular, heater assemblies in which the porous material is a ceramic material have been proposed. The liquid aerosol-forming substrate is supplied from the liquid storage portion to the heating element through the pores of the porous material by capillary action. The heat generated by the heating element may be conducted through the porous material away from the heated surface.

[0006] However, it has been observed that the ceramic pores must be relatively large in order for sufficient liquid to be supplied to the heating element and to prevent dry heating. Undesirably, this can sometimes accidentally lead to an excess of liquid being supplied to the heating surface, which can lead to liquid leakage.

[0007] Furthermore, the ceramic materials from which the porous bodies are fabricated are generally very rigid, which can complicate the integration of the porous bodies into cartridges, particularly in terms of relatively tight tolerances. In known cartridges, attempts have been made to address this by providing a silicone cap on top of the porous body.

[0008] It is desirable to provide a cartridge for an aerosol generation system that substantially prevents leakage of the liquid aerosol-forming substrate while simultaneously being adapted to withstand so-called dry heating. To reduce the risk of damaging the heater assembly during cartridge manufacturing, it is desirable to provide a cartridge for an aerosol generation system that is easy to assemble. [Overview of the Initiative]

[0009] This disclosure relates to a cartridge for an aerosol generation system.

[0010] The cartridge may comprise a cartridge body. The cartridge body may include a liquid storage portion for holding a liquid aerosol-forming substrate. The cartridge may comprise a heater assembly. The heater assembly may comprise a heating element for vaporizing the liquid aerosol-forming substrate. The heater assembly may further comprise a porous ceramic body for transporting the liquid aerosol-forming substrate from the liquid storage portion to the heating element. The cartridge may comprise a sealing element configured to provide a sealing engagement between the porous ceramic body and the cartridge body.

[0011] The sealing element may contain cotton or polyethylene (PE). The sealing element may contain 50% or more by weight of cotton or polyethylene (PE). The sealing element may be made of cotton or polyethylene (PE).

[0012] The sealing element may contain thermoplastic elastomer (TPE). The sealing element may contain 50 weight percent or more of thermoplastic elastomer (TPE). The sealing element may be made of thermoplastic elastomer (TPE).

[0013] The sealing element may contain silicone-free rubber. The sealing element may contain 50 weight percent or more of silicone-free rubber. The sealing element may be made of silicone-free rubber.

[0014] According to a first aspect of the present invention, a cartridge for an aerosol generating system is provided, comprising: a cartridge body having a liquid storage portion for holding a liquid aerosol forming substrate; a heater assembly having a heating element for vaporizing the liquid aerosol forming substrate and a porous ceramic body for transporting the liquid aerosol forming substrate from the liquid storage portion to the heating element; and a sealing element configured to provide a sealing engagement between the porous ceramic body and the cartridge body. The sealing element comprises a) cotton or one of polyethylene (PE), thermoplastic elastomer (TPE), or silicone-free rubber.

[0015] This disclosure also relates to an aerosol generating system. The aerosol generating system may include a cartridge as described above. The aerosol generating system may include an aerosol generating device. The aerosol generating device may include a power supply for supplying power to the heater assembly of the cartridge. The aerosol generating device may include a control circuit for controlling the power supply from the power supply to the heater assembly.

[0016] According to a second aspect of the present invention, an aerosol generating system is provided, comprising a cartridge according to the first aspect of the present invention, an aerosol generating device comprising a power supply for supplying power to a heater assembly of the cartridge, and a control circuit for controlling the supply of power from the power supply to the heater assembly of the cartridge.

[0017] In the cartridge for the aerosol generating system according to the present invention, the sealing element is advantageously wound around the porous ceramic body of the heater assembly and adapted to be interposed between the porous ceramic body and the cartridge body. In addition to preventing leakage of the liquid aerosol-forming substrate, such arrangement facilitates the assembly of the porous ceramic body into the cartridge. This is because the inherent flexibility of cotton, polyethylene (PE), thermoplastic elastomer (TPE), and silicone-free rubber advantageously compensates, at least partially, for tight geometric and dimensional tolerances of the heater assembly and the cartridge body.

[0018] Simultaneously, a sealing element comprising cotton or one of polyethylene (PE), thermoplastic elastomer (TPE), and silicone-free rubber is advantageously adapted to protect the outer surface of the porous ceramic body of the heater assembly from wear and tear that may be caused by friction between the porous ceramic body and the cartridge body.

[0019] In contrast to certain existing cartridges for aerosol generating systems in which a silicone-based sealing element is provided between the heater assembly and the cartridge body, the cartridge for an aerosol generating system according to the present invention has the additional advantage that, even when the liquid aerosol-forming substrate is heated, siloxanes, which are functional groups that form the silicone backbone, are not released from the sealing element during use and do not enter the aerosol delivered to the user. This is desirable because certain siloxanes, such as D4 (octamethylcyclotetrasiloxane) and D5 (decamethylcyclopentasiloxane), have been identified as hazardous substances due to their persistence and bioaccumulation, and can cause health problems if inhaled.

[0020] As used herein, the term "aerosol generator" refers to a device that interacts with a liquid aerosol-forming substrate in order to generate an aerosol.

[0021] As used herein, the terms “cartridge” and “aerosol generating cartridge” refer to components that interact with a liquid aerosol generating apparatus for generating an aerosol. An aerosol generating cartridge contains, or is configured to contain, a liquid aerosol-forming substrate.

[0022] As used herein, the term “liquid aerosol-forming substrate” refers to a liquid substrate having the ability to release volatile compounds that can form aerosols. Such volatile compounds may be released by heating the aerosol-forming substrate.

[0023] As used herein, “heating element” refers to a component that transfers thermal energy to a liquid aerosol-forming substrate.

[0024] As used herein, the term “porous material” refers to a component having multiple pores, at least some of which are interconnected. A porous material has a liquid-absorbing surface, i.e., a surface that is exposed to and can come into direct contact with a liquid aerosol-forming substrate. A porous material has a heating surface, i.e., a surface on which a heating element may be located.

[0025] As briefly described above, the cartridge for the aerosol generation system according to the present invention comprises a heater assembly. The heater assembly comprises a heating element for vaporizing a liquid aerosol-forming substrate and a porous ceramic body for transporting the liquid aerosol-forming substrate to the heating element.

[0026] The porous body may have a liquid adsorption surface. The porous body may have a heating surface. The heating element may be placed on the heating surface of the porous body.

[0027] The porous ceramic body contains multiple voids. These voids are interconnected to provide a fluid pathway for the liquid aerosol-forming substrate through the porous body from the liquid absorption surface to the heating surface.

[0028] The porous ceramic body may include at least one of an oxide ceramic material, a non-oxide ceramic material, and a glass-ceramic material. The porous ceramic body preferably includes at least one of alumina, aluminosilicate, zirconia, silicon carbide, silicon nitride, lithium aluminosilicate glass-ceramic, silicide material, and boride material.

[0029] The porous ceramic body may include a capillary material that transports a liquid aerosol-forming substrate through the material by capillary action. The porous ceramic body may have a fibrous structure or a porous structure. The porous ceramic body may include a bundle of capillaries. For example, the porous ceramic body may include a plurality of fibers or threads, or other fine tubes. The porous ceramic body may include, for example, a ceramic-based fibrous material.

[0030] The pores of the porous body may have any shape. The pores of the porous body may be interconnected pores. The porous body may include a plurality of longitudinally extending pores that extend from the liquid adsorption surface of the porous body to the heating surface of the porous body.

[0031] The provision of longitudinally extending pores may advantageously facilitate the efficient movement of the liquid aerosol-forming substrate from the liquid adsorption surface of the porous body to the heating surface of the porous body.

[0032] The average pore size of the porous body may vary between the liquid adsorption surface and the heating surface.

[0033] The provision of a porous body that includes a variation in pore size between the liquid adsorption surface and the heating surface may advantageously serve to control the transport of the liquid aerosol-forming substrate from the storage portion of the liquid aerosol-forming substrate to the heating element. Specifically, the variation in pore size between the liquid adsorption surface and the heating surface may make it possible for the porous body to provide a consistent supply of the aerosol-forming substrate to the heating surface. This may advantageously contribute to avoiding undesirable "dry heating".

[0034] The average pore size of a porous material can vary considerably between the liquid adsorption surface and the heated surface. The average pore size can range from relatively large pores on the liquid adsorption surface to relatively small pores on the heated surface.

[0035] The porous body may have a heating end and a liquid adsorption end, with the heating surface located at the heating end and the liquid adsorption surface located at the liquid adsorption end. The porous body may have a first average pore size at the liquid adsorption end and a second average pore size at the heating end, where the first average pore size is larger than the second average pore size.

[0036] Providing a porous body having a larger average pore size at the liquid adsorption end and a smaller average pore size at the heating end may particularly facilitate the efficient transfer of a liquid aerosol-forming substrate from the liquid adsorption end to the heating end of the porous body without allowing leakage. In particular, the inventors of the present invention have identified that the liquid aerosol-forming substrate is transferred from the liquid adsorption end to the heating end of the porous body by capillary action. How quickly the liquid aerosol-forming substrate moves through the porous body depends on many factors, including but not limited to the shape of the pores, the surface tension between the liquid aerosol-forming substrate and the porous body, the viscosity of the liquid aerosol-forming substrate, and the surface tension of the liquid aerosol-forming substrate. The inventors of the present invention have identified the need to balance these factors and provide efficient transfer of the liquid aerosol-forming substrate to the heating surface of the porous body while preventing leakage of the liquid aerosol-forming substrate.

[0037] Firstly, to provide efficient capillary flow of liquid through the porous material, the capillary pressure must exceed the viscous drag pressure. Secondly, to prevent leakage, the inertial force must not exceed the capillary pressure. These two requirements are met by providing a porous material having larger pores at the liquid adsorption end and smaller pores at the heating end.

[0038] The porous ceramic body may include a surface extending along its long axis between the liquid adsorption surface and the heating surface. This surface may be impermeable to liquid. The heating element and the porous ceramic body may be integrally formed.

[0039] The porous ceramic body may include longitudinal grooves extending along the longitudinal surface of the porous ceramic body between the liquid absorption surface and the heating surface.

[0040] The longitudinal grooves may extend all the way from the liquid-absorbing surface of the porous ceramic body to the heating surface of the porous ceramic body. Providing longitudinal grooves can allow air to pass from the liquid-absorbing surface of the porous ceramic body to the heating surface of the porous ceramic body. During use, the longitudinal grooves can advantageously direct and guide air toward the heating surface of the porous ceramic body when the user inhales the aerosol generating system. As the air passes through the heating surface, it may mix with the aerosol generated by the heating element before being delivered to the user.

[0041] The porous ceramic body may have two or more longitudinal grooves. For example, the porous ceramic body may have at least two, at least three, at least four, or at least five longitudinal grooves. If the porous ceramic body has multiple longitudinal grooves, the longitudinal grooves may be evenly distributed around the porous ceramic body.

[0042] The porous ceramic body may have a substantially constant cross-section. For example, the cross-sectional area of ​​the liquid-absorbing surface of the porous ceramic body may be substantially the same as the cross-sectional area of ​​the heating surface.

[0043] The porous ceramic body may have any shape. For example, the porous ceramic body may be substantially cylindrical. In this case, both the liquid absorption surface and the heating surface may be circular. The porous ceramic body may have a regular cubic shape. In this case, both the liquid absorption surface and the heating surface may be square.

[0044] The liquid-absorbing surface of the porous ceramic body may have a region different from the heated surface region of the porous body. The surface area of ​​the heated surface may be larger than the surface area of ​​the liquid-absorbing surface.

[0045] The surface area of ​​the liquid-absorbing surface may be larger than the surface area of ​​the liquid-absorbing surface itself.

[0046] The porous ceramic body may have any cross-sectional shape. The porous ceramic body may have a rectangular or circular cross-sectional shape.

[0047] The heating element may be any type of heating element. The heating element may be fluid permeable.

[0048] As used herein in relation to the present invention, the term "fluid permeability" in the context of a heating element means that a liquid aerosol-forming substrate can pass from one side of the heating element to the other side without having to travel around the heating element.

[0049] For a heating element to be fluid-permeable, it is understood that the material from which the heating element is made must be fluid-permeable. Alternatively, the material from which the heating element is made may be fluid-impermeable, but nevertheless, depending on the structure or arrangement of the heating element, it may be possible to allow a liquid aerosol-forming substrate to pass from one side of the heating element to the other.

[0050] The heating element may be an electrically heated element. For example, the heating element may be a resistance heating element. The heating element may have any preferred shape or form. Examples of preferred shapes and forms, but are not limited to, include strips, flakes, filaments, wires, meshes, flat spiral coils, fibers, or cloths.

[0051] In some preferred examples, the heating element is planar. A planar heating element may extend substantially within a plane.

[0052] In some preferred examples, the heating element comprises a mesh. The heating element may comprise an array of filaments forming a mesh. As used herein, the term "mesh" means

[0053] This includes grids and arrays of filaments with spaces in between. The term mesh also includes woven and nonwoven fabrics.

[0054] The filaments may be formed by etching a sheet material such as foil. This can be particularly advantageous when the heater assembly comprises an array of parallel filaments.

[0055] If the heating element comprises a mesh or fabric of filaments, the filaments may be formed individually or knitted together.

[0056] The heating element may include an electrically resistant heating element. The heating element may be made from any suitable conductive material. Suitable materials include, but are not limited to, semiconductors such as doped ceramics, conductive ceramics (e.g., molybdenum disilide), carbon, graphite, metals, alloys, and composite materials made of ceramic and metallic materials. Such composite materials may include doped or undoped ceramics. A suitable example of a doped ceramic is doped silicon carbide. Suitable examples of metals include titanium, zirconium, tantalum, and platinum group metals. Suitable alloys include stainless steel, constantan, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel, iron, cobalt, stainless steel-based superalloys, Timetal®, iron-aluminum alloys, and iron-manganese-aluminum alloys. Timetal® is a registered trademark of Titanium Metals Corporation. The heating element may be made from stainless steel, such as 300 series stainless steels, including AISI 304, 316, 304L, and 316L. In a preferred example, the electric heating element may comprise one or more of NiCr and TiZr.

[0057] Additionally, the heating element may comprise the above-mentioned combination of materials. Combinations of materials may be used to improve the control of the heating element's resistance. For example, a material with high resistivity may be combined with a material with low resistivity. This may be advantageous if one of the materials is more beneficial in terms of other respects, such as price, machinability, or other physical and chemical parameters. Advantageously, heating at high resistance allows for more efficient use of battery energy.

[0058] The electric heating element may be formed from a conductive material deposited on a porous element. As used herein, the term "conductive material" refers to a material having a resistivity of 1 x 10⁻² Ωm or less. As used herein, the term "deposited" means applied as a layer or coating by a physical or chemical process, for example, in the form of a liquid, plasma, or vapor, in which case the layer or coating does not simply lay on or fix to the porous material as a pre-formed solid component, but rather subsequently condenses or aggregates to form the electric heating element.

[0059] The electric heating element may be deposited directly onto the porous outer surface. In other words, the conductive material forming the electric heating element is deposited onto the porous material such that the electric heating element is in direct contact with the porous material.

[0060] In some examples, the conductive material of the electric heating element may diffuse at least partially into the porous material. As used herein, the term “diffuse into the porous material” means that the conductive material is incorporated into the porous material by extending, for example, into the pores of the porous material at the interface between the conductive material and the porous material. This arrangement may further improve the heating of the liquid aerosol-forming substrate and aerosol delivery by fixing the electric heating element to the porous material and by increasing contact between the electric heating element and the porous material.

[0061] The conductive material forming the electric heating element may be deposited onto the porous body in any suitable manner. For example, the conductive material may be deposited onto the porous body as a liquid using a dispensing pipette or syringe, or using a micro-tip transfer device such as a needle.

[0062] In some examples, at least one heating element comprises a printable conductive material printed on a porous body. In such embodiments, any suitable known printing technique may be used, for example, one or more of screen printing, gravure printing, flexographic printing, or inkjet printing. Such printing processes may be particularly applicable to high-speed manufacturing processes.

[0063] Alternatively, the conductive material forming the electric heating element may be deposited onto the porous body by one or more vacuum deposition processes, such as vapor deposition and sputtering.

[0064] At least one heating element may be formed from any suitable conductive material. In certain preferred embodiments, the conductive material comprises one or more of metals, conductive polymers, and conductive ceramics.

[0065] Suitable conductive metals include, but are not limited to, aluminum, silver, nickel, gold, platinum, copper, tungsten, and alloys thereof. In some embodiments, the conductive material comprises metal powder suspended in an adhesive such as epoxy resin. In one embodiment, the conductive material comprises silver-adhered epoxy.

[0066] Suitable conductive polymers include PEDOT (poly(3,4-ethylenedioxythiophene)), PSS (poly(p-phenylene sulfide)), PEDOT:PSS (a mixture of PEDOT and PSS), PANI (polyaniline), PPY (poly(pyrrole)), PPV (poly(p-phenylene vinylene)), or combinations thereof.

[0067] Suitable conductive ceramics include ITO (indium tin oxide), SLT (lanthanum-doped strontium titanate), SYT (yttrium-doped strontium titanate), or combinations thereof.

[0068] The conductive material may further comprise one or more additives selected from the group consisting of solvents, curing agents, adhesion promoters, surfactants, viscosity reducers, and aggregation inhibitors. Such additives may be used, for example, to assist in the deposition of the conductive material onto the porous outer surface of a porous body, to increase the amount of the conductive material that diffuses into the porous outer surface of a porous body, to shorten the time until the conductive material hardens, to increase the degree of adhesion between the conductive material and the porous body, or to reduce the amount of agglomeration of suspended particles, such as metal particles or powders, within the conductive material before the conductive material is applied to the porous outer surface of a porous body.

[0069] The heater assembly may further include an insulating layer having a lower thermal conductivity than the porous ceramic body, the insulating layer being positioned between the porous ceramic body and the heating element and in contact with them, and configured to reduce heat transfer from the heating element to the porous ceramic body.

[0070] As briefly described above, the cartridge for the aerosol generation system according to the present invention comprises a cartridge body having a liquid storage portion for holding a liquid aerosol forming substrate.

[0071] The cartridge body may be formed from a durable material. The cartridge body may be formed from a liquid-impermeable material. The cartridge body may be formed from a moldable plastic material such as polypropylene (PP) or polyethylene terephthalate (PET). The cartridge body may define a portion of the liquid storage area, i.e., the storage section. The cartridge housing may define the liquid storage area. The cartridge body and the liquid storage area may be formed integrally. Alternatively, the liquid storage area may be formed separately from the cartridge body or disposed within the cartridge body.

[0072] The liquid aerosol-forming substrate may be liquid at room temperature. The liquid aerosol-forming substrate may contain both liquid and solid components. The liquid aerosol-forming substrate may contain nicotine. A nicotine-containing liquid aerosol-forming substrate may also be a nicotine salt matrix. The liquid aerosol-forming substrate may contain plant-derived materials. The liquid aerosol-forming substrate may contain tobacco. The liquid aerosol-forming substrate may contain tobacco-containing materials that contain volatile tobacco-flavored compounds released from the aerosol-forming substrate upon heating. The liquid aerosol-forming substrate may contain homogenized tobacco materials. The liquid aerosol-forming substrate may contain non-tobacco-containing materials. The liquid aerosol-forming substrate may contain homogenized plant-derived materials.

[0073] A liquid aerosol-forming substrate may comprise one or more aerosol-forming elements. An aerosol-forming element is any suitable known compound, or mixture of compounds, that facilitates the formation of a high-density, stable aerosol during use and is substantially resistant to thermal decomposition at the system's operating temperature. Examples of suitable aerosol-forming elements include glycerin and propylene glycol. Suitable aerosol-forming elements are well known in the art and include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (e.g., dimethyl dodecanediol, dimethyl tetradecanediol). The liquid aerosol-forming substrate may also contain water, a solvent, ethanol, plant extracts, and natural or artificial flavors.

[0074] The liquid aerosol-forming substrate may contain nicotine and at least one aerosol-forming agent. The aerosol-forming agent may be glycerin or propylene glycol. The aerosol-forming agent may contain both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of about 0.5% to about 10% by weight, for example, about 2% by weight.

[0075] Furthermore, the cartridge for the aerosol generation system according to the present invention includes a sealing element configured to provide a sealing engagement between the porous ceramic body of the heater assembly and the cartridge body.

[0076] In some embodiments, the sealing element includes a cup-shaped body configured to be positioned on the porous ceramic body of the heater assembly. The cup-shaped body preferably has an opening at one end and defines an internal cavity for receiving at least a portion of the porous ceramic body. The overall shape and volume of the internal cavity more preferably substantially match the overall shape and volume of the porous ceramic body. Therefore, the cup-shaped body of the sealing element may be tightly wound around the periphery of the porous ceramic body to hold it in a particularly secure manner. This advantageously ensures the provision of a particularly tight and stable sealing engagement between the porous ceramic body and the cartridge body.

[0077] In certain embodiments, the sealing element comprises cotton or polyethylene (PE). Preferably, the sealing element comprises at least 50 weight percent of cotton or polyethylene (PE). More preferably, the sealing element comprises at least about 60 weight percent, or at least 70 weight percent, or at least 80 weight percent, or at least 90 weight percent of cotton or polyethylene (PE).

[0078] In certain preferred embodiments, the sealing element comprises 95% by weight or more of cotton or polyethylene (PE).

[0079] In a particularly preferred embodiment, the sealing element is substantially made entirely of cotton or polyethylene (PE).

[0080] The use of cotton or polyethylene (PE) is beneficial in that the sealing element exhibits good flexibility and a certain degree of liquid retention capacity. At the same time, sealing elements made from cotton or polyethylene (PE) have been found to be particularly effective in protecting the porous ceramic body of the heater assembly from damage that may occur during manufacturing and assembly, as well as during accidental drops of the aerosol generating system.

[0081] In contrast to known cartridges for aerosol generating systems in which the heater assembly is wrapped in a silicone sealing element, the cartridge according to the present invention, which includes a cotton or PE sealing element, exhibits extremely low or no siloxane emissions (less than 100 nanograms / 100 smoke inhalations).

[0082] The density of polyethylene (PE) is preferably at least 0.91 grams / cubic centimeter. The density of polyethylene (PE) is preferably 0.96 grams / cubic centimeter or less. In certain embodiments, the density of polyethylene (PE) is between 0.91 grams / cubic centimeter and 0.96 grams / cubic centimeter.

[0083] In certain embodiments, the sealing element comprises a thermoplastic elastomer (TPE). Preferably, the sealing element comprises at least 50 weight percent of a thermoplastic elastomer (TPE). More preferably, the sealing element comprises at least about 60 weight percent, or at least 70 weight percent, or at least 80 weight percent, or at least 90 weight percent of a thermoplastic elastomer (TPE).

[0084] In certain preferred embodiments, the sealing element comprises 95% by weight or more of thermoplastic elastomer (TPE).

[0085] In a particularly preferred embodiment, the sealing element is made substantially entirely of thermoplastic elastomer (TPE).

[0086] Thermoplastic elastomers (TPEs) have been found to be particularly suitable for accommodating tight tolerances and facilitating the assembly of heater components into the cartridge body. Furthermore, they form an impermeable protective surface adapted to ensure a particularly tight seal of the heater assembly within the cartridge. Sealing elements made from thermoplastic elastomers (TPEs) have a smooth and soft finish, which is particularly suitable for winding the porous ceramic body of the heater assembly, minimizing the risk of damaging the porous ceramic body during cartridge manufacturing.

[0087] In contrast to known cartridges for aerosol generating systems in which the heater assembly is wrapped in a silicone sealing element, the cartridge according to the present invention, which includes a TPE sealing element, exhibits extremely low or no siloxane emissions (less than 100 nanograms / 100 smoke inhalations).

[0088] The thermoplastic elastomer preferably has a Shore A hardness of 60 to 80.

[0089] As used herein, the term "Shore A hardness" is used to describe the durometer hardness of rubber-like materials and is evaluated according to ASTM D2240 (2015). The test effectively measures how far a specified intruder penetrates a sample of the material under specified force and time conditions. For this purpose, the sample is placed on a hard, flat surface. The intruder of the instrument is then pressed into the sample, ensuring that it is parallel to the surface. The hardness is read within one second of firm contact with the sample. The test sample is typically 6.4 millimeters thick. While it is possible to stack several samples to achieve a thickness of 6.4 millimeters, the use of a single sample is preferred.

[0090] The thermoplastic elastomer more preferably has a Shore A hardness of 65 to 75. In a particularly preferred embodiment, the thermoplastic elastomer has a Shore A hardness of 70.

[0091] The inventors found that TPE having a Shore A hardness within the above range is flexible enough to encase a ceramic porous heater while simultaneously providing desirable protection against abrasion and fracture.

[0092] An example of a suitable thermoplastic elastomer for use in the sealing element of the cartridge according to the present invention is THERMOLAST®, which is commercially available from KRAIBURG TPE GmbH & Co. KG.

[0093] In certain embodiments, the sealing element comprises silicone-free rubber. Preferably, the sealing element comprises at least 50 weight percent of silicone-free rubber. More preferably, the sealing element comprises at least about 60 weight percent, or at least 70 weight percent, or at least 80 weight percent, or at least 90 weight percent of silicone-free rubber.

[0094] In certain preferred embodiments, the sealing element comprises 95% by weight or more silicone-free rubber.

[0095] In a particularly preferred embodiment, the sealing element is substantially entirely made of silicone-free rubber.

[0096] In some embodiments, the silicone-free rubber is an unsaturated rubber that can be cured by sulfur vulcanization. For example, the silicone-free rubber may be selected from the group consisting of natural polyisoprene (cis-1,4-polyisoprene natural rubber (NR) and trans-1,4-polyisoprene galvanic ta-percha), synthetic polyisoprene, polybutadiene (BR), chloroprene rubber (CR), polychloroprene, neoprene, biprene, butyl rubber (IIR), halogenated butyl rubber (BIIR), styrene-butadiene rubber (SBR), nitrile rubber (NBR), and hydrogenated nitrile rubber (HNBR).

[0097] In other embodiments, the silicone-free rubber is a saturated rubber that cannot be cured by sulfur vulcanization. For example, the silicone-free rubber may be selected from the group consisting of EPM (ethylene propylene rubber, ethene and propene copolymer) and EPDM rubber (ethylene propylene diene rubber, ethylene terpolymer, propylene and diene component), epichlorohydrin rubber (ECO), polyacrylic rubber (ACM, ABR), fluoroelastomers (FKM, and FEPM) Viton, Technoflon, Fluorel, Aflas and Dai-El, perfluoroelastomer (FFKM) Technoflon PFR, Kalrez, Chemraz, Perlast, polyether block amide (PEBA), chlorosulfonated polyethylene (CSM), (Hypalon), and ethylene vinyl acetate (EVA).

[0098] In further embodiments, the silicone-free rubber is a 4S elastomer. For example, the silicone-free rubber may be selected from the group consisting of resilin, elastin, polysulfide rubber, elastolevine, and poly(dichlorophosphazene).

[0099] The silicone-free rubber of the aforementioned type has been found to be well-suited to provide an impermeable protective surface around the heater assembly and to particularly tightly seal the heater assembly within the cartridge. Sealing elements made from the silicone-free rubber of the aforementioned type, exhibiting a smooth and soft finish, can be provided. This makes such sealing elements particularly suitable for wrapping around the porous ceramic body of the heater assembly, minimizing the risk of damaging the porous ceramic body during cartridge manufacturing.

[0100] In contrast to known cartridges for aerosol generating systems in which the heater assembly is wrapped in a silicone sealing element, the cartridge according to the present invention, which includes a silicone-free rubber sealing element, exhibits extremely low or no siloxane emissions (less than 100 nanograms / 100 smoke inhalations).

[0101] The cartridge may have a mouthpiece located at the oral end of the cartridge. The mouthpiece may have an aerosol outlet through which the generated aerosol may be inhaled by the user. The cartridge may have a connection terminal configured to connect the cartridge to an aerosol generator.

[0102] The cartridge may have an air intake. The cartridge may have an enclosed airflow passage from the air intake to the aerosol outlet. The enclosed airflow passage may extend from the air intake through the heater assembly to the aerosol outlet. The enclosed airflow passage may pass around the outer surface of the liquid storage portion. Alternatively, the enclosed airflow passage may pass through the liquid storage portion. For example, the liquid storage portion may have an annular cross-section defining an internal passage, and the airflow passage may extend through the internal passage of the liquid storage portion.

[0103] The cartridge may include a first airflow path extending in a first direction from the air intake towards the heater assembly. The cartridge may also include a second airflow path extending through the electric heating element and configured to entrain aerosols. The cartridge may also include a third airflow path extending in a second direction from the heater assembly towards the aerosol outlet. The second direction may be opposite to the first direction. The second airflow path may provide a fluid connection between the first and third airflow paths.

[0104] As mentioned above, the cartridge described above is used in an aerosol generating system that includes an aerosol generator comprising a cartridge, a power supply for supplying power to the heater assembly of the cartridge, and a control circuit for controlling the power supply from the power supply to the heater assembly of the cartridge.

[0105] The cartridge may include a liquid aerosol-forming substrate within the liquid storage portion. The liquid aerosol-forming substrate may be as described above.

[0106] The aerosol generating system may be portable. The aerosol generating system may be comparable in size to a conventional cigar or cigarette.

[0107] The aerosol generator may include a housing. The housing may be elongated. The housing may be made of any suitable material, or a combination of such materials. Examples of suitable materials include metals, alloys, plastics, or composite materials containing one or more of these materials, or thermoplastic resins suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), and polyethylene. The material is preferably lightweight and non-brittle.

[0108] The housing of the aerosol generator may define a cavity or recess for receiving a portion of the cartridge. The aerosol generator may have a connecting end configured to detachably connect to the cartridge. The connecting end may have a cavity or recess for receiving the cartridge.

[0109] The aerosol generator may have a distal end opposite to the connection end. The distal end may include an electrical connector configured to connect the aerosol generator to an electrical connector of an external power supply in order to charge the power supply of the aerosol generator.

[0110] The aerosol generator may include a control circuit. The control circuit may include any suitable controller or electrical component. The controller may include memory. Information for carrying out the above-described method may be stored in memory. The control circuit may include a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller, or an application-specific integrated circuit (ASIC) or other electronic circuit capable of providing control. The control circuit may be configured to supply power to the heating element continuously after the device is started, or to supply power intermittently, such as with each smoke extraction. Power may be supplied to the heating element in the form of current pulses, for example by pulse-width modulation (PWM). The control circuit may include further electronic components. For example, in some embodiments, the control circuit may include a sensor element, a switch element, or a display element.

[0111] The aerosol generator may include a power source in the form of a battery. The battery may be rechargeable. The battery may be a lithium-based battery, such as a lithium cobalt battery, lithium iron phosphate battery, lithium titanate battery, or lithium polymer battery. The battery may be a nickel-metal hydride battery or a nickel-cadmium battery. The power source may be another form of charge storage device, such as a capacitor. The power source may be rechargeable and may be configured to undergo multiple charge-discharge cycles. The power source may have a capacity that allows for the storage of sufficient energy for one or more user experiences of the aerosol generator system. For example, the power source may have a capacity that allows for continuous aerosol generation for about six minutes, or a multiple of six minutes, corresponding to the typical time it takes to smoke one conventional cigarette. In another embodiment, the power source may have a capacity that allows for a predetermined number of puffs or discontinuous startups of the aerosol generator system. [Examples]

[0112] A non-exclusive list of non-limiting embodiments is provided below. One or more features of these embodiments may be combined with one or more features of other embodiments, or forms, or aspects described herein.

[0113] Example 1: A cartridge for an aerosol generation system, comprising: a cartridge body having a liquid storage portion for holding a liquid aerosol forming substrate; a heater assembly having a heating element for vaporizing the liquid aerosol forming substrate and a porous ceramic body for transporting the liquid aerosol forming substrate from the liquid storage portion to the heating element; and a sealing element configured to provide a sealing engagement between the porous ceramic body and the cartridge body. Example 2: The cartridge according to Example 1, wherein the sealing element comprises cotton or polyethylene (PE). Example 3: The cartridge according to Example 2, wherein the sealing element comprises at least 50 weight percent of cotton or polyethylene (PE). Example 4: The cartridge according to Example 2, wherein the sealing element comprises at least 60 weight percent of cotton or polyethylene (PE). Example 5: The cartridge according to Example 2, wherein the sealing element comprises at least 70 weight percent of cotton or polyethylene (PE). Example 6: The cartridge according to Example 2, wherein the sealing element comprises at least 80 weight percent of cotton or polyethylene (PE). Example 7: The cartridge according to Example 2, wherein the sealing element comprises at least 90 weight percent cotton or polyethylene (PE). Example 8: The cartridge according to Example 2, wherein the sealing element comprises at least 95% by weight of cotton or polyethylene (PE). Example 9: The cartridge according to Example 2, wherein the sealing element is substantially made entirely of cotton or polyethylene (PE). Example 10: The cartridge according to Example 1, wherein the sealing element includes a thermoplastic elastomer (TPE). Example 11: The cartridge according to Example 10, wherein the sealing element comprises at least 50 weight percent of thermoplastic elastomer (TPE). Example 12: The cartridge according to Example 10, wherein the sealing element comprises at least 60 weight percent of thermoplastic elastomer (TPE). Example 13: The cartridge according to Example 10, wherein the sealing element comprises at least 70 weight percent of thermoplastic elastomer (TPE). Example 14: The cartridge according to Example 10, wherein the sealing element comprises at least 80 weight percent of thermoplastic elastomer (TPE). Example 15: The cartridge according to Example 10, wherein the sealing element comprises at least 90 weight percent of thermoplastic elastomer (TPE). Example 16: The cartridge according to Example 10, wherein the sealing element comprises at least 95 weight percent of thermoplastic elastomer (TPE). Example 17: The cartridge according to Example 10, wherein the sealing element is substantially entirely made of thermoplastic elastomer (TPE). Example 18: The cartridge according to Example 1, wherein the sealing element includes silicone-free rubber. Example 19: The cartridge according to Example 18, wherein the sealing element comprises at least 50 weight percent silicone-free rubber. Example 20: The cartridge according to Example 18, wherein the sealing element comprises at least 60 weight percent silicone-free rubber. Example 21: The cartridge according to Example 18, wherein the sealing element comprises at least 70 weight percent silicone-free rubber. Example 22: The cartridge according to Example 18, wherein the sealing element comprises at least 80 weight percent silicone-free rubber. Example 23: The cartridge according to Example 18, wherein the sealing element comprises at least 90 weight percent silicone-free rubber. Example 24: The cartridge according to Example 18, wherein the sealing element comprises at least 95 weight percent silicone-free rubber. Example 25: The cartridge according to Example 18, wherein the sealing element is substantially entirely made of silicone-free rubber. Example 26: The polyethylene is a cartridge according to any one of Examples 2 to 9, having a density of 0.91 g / cm³ to 0.96 g / cm³. Example 27: A cartridge as described in any one of Examples 10 to 17.

[0114] Next, the examples will be further described with reference to the attached figures. [Brief explanation of the drawing]

[0115] [Figure 1] Figure 1 is a schematic cross-sectional view of an aerosol generation system according to one embodiment of the present disclosure. [Figure 2A] Figure 2A is a schematic perspective view of the porous ceramic body of the heater assembly of the aerosol generation system shown in Figure 1. [Figure 2B] Figure 2B is another schematic perspective view of the porous ceramic body shown in Figure 2A. [Figure 2C] Figure 2C is a schematic perspective view of a sealing element configured to provide a sealing engagement between the porous ceramic body shown in Figures 2A and 2B and the cartridge body in the aerosol generating system shown in Figure 1.

[0116] It should be understood that the figures in this application are schematic and simplified for clarity. As a result, some features may be omitted, and features are not necessarily shown to scale. [Modes for carrying out the invention]

[0117] References to orientation, such as vertical, horizontal, up, down, upper side, and lower side, when describing the features of this disclosure are not intended to limit the orientation of those features, but are simply intended to show the relative spatial arrangement of the features, particularly with reference to the figures or in normal use. It will be understood that the features of this disclosure may have different orientations when used.

[0118] Referring to Figure 1, an aerosol generating system 10 according to an embodiment of the present disclosure is schematically shown. The aerosol generating system 10 comprises two main components, namely a cartridge 100 and a main body, namely an aerosol generating device 200. The aerosol generating device 200 comprises a housing 202 adapted to receive each of the connection ends 102 of the cartridge 100 at one end. More specifically, the cartridge 100 is detachably connectable to the aerosol generating device 200 by inserting the connection ends 102 of the cartridge 100 into recesses defined within the aerosol generating device 200. The connection ends 102 of the cartridge 100 and the recesses of the aerosol generating device 200 each have electrical contacts or connectors (not shown) arranged to cooperate to provide an electrical connection between the cartridge 100 and the aerosol generating device 200. The aerosol generator 200 houses a power source in the form of a rechargeable lithium-ion battery 204, and a control circuit 206. The aerosol generating system 50 is portable and is about the same size as a conventional cigar or cigarette.

[0119] The cartridge 100 comprises a cartridge body 104. The cartridge body 104 defines a mouthpiece 106 at the end opposite to the connection end 102. Furthermore, the cartridge body 104 defines a storage section, or liquid storage section 108, for holding the liquid aerosol forming substrate 110. The liquid storage section 108 has an opening at its lower end or base, and the heater assembly 112 is disposed within this opening.

[0120] The heater assembly 112 includes a heating element 116 and a porous ceramic body 118.

[0121] The heating element 116 is configured to vaporize an aerosol-forming substrate, such as a liquid aerosol-forming substrate, to form an aerosol. The heating element 116 is configured to convert electrical energy into thermal energy and then electric current through the material resistance of the heating element 116.

[0122] The porous ceramic body 118 is configured to transport the liquid aerosol-forming substrate to the heating element 116. In other words, the porous ceramic body 118 supplies the liquid aerosol-forming substrate to the heating element 116.

[0123] Figures 2A and 2B show two perspective views of the porous ceramic body 118 of the cartridge 100 in Figure 1.

[0124] The porous ceramic body 118 has a first end face and an opposing second end face. The first end face is the liquid absorption surface 130, and the second end face is the heating surface 140. In the embodiments of Figures 2A and 2B, both the liquid absorption surface 130 and the heating surface 140 are substantially flat surfaces. The porous ceramic body 118 also has a plurality of sides extending between the liquid absorption surface 130 and the heating surface 140. In this embodiment, the porous ceramic body 118 has a first side face 150 opposite to a second side face 160, and a third side face 170 opposite to a fourth side face 180.

[0125] The porous ceramic body 118 contains multiple voids. These voids are interconnected to provide a fluid pathway for the liquid aerosol-forming substrate through the porous body 118 from the liquid absorption surface 130 to the heating surface 140. The porous body 118 is formed from a ceramic material that does not chemically interact with the liquid aerosol-forming substrate, such as Ca2SiO3 or SiO2 (or Ca2SiO3 and SiO2).

[0126] The cartridge 100 further comprises a sealing element 300 configured to provide a sealing engagement between the porous ceramic body 118 and the cartridge body 104. A schematic perspective view of the sealing element 300 is shown in Figure 2C.

[0127] The sealing element 300 includes a substantially parallelepiped cup-shaped body 302 configured to be placed on the porous ceramic body 118. The cup-shaped body 302 has an opening 304 at one end and defines an internal cavity 306 for receiving the porous ceramic body 118. The overall shape and volume of the internal cavity 306 substantially match the overall shape and volume of the porous ceramic body 118, so that the cup-shaped body 302 of the sealing element 300 can be tightly wrapped around the periphery of the porous ceramic body 118.

[0128] In the embodiment shown in Figure 1, the sealing element is made of polyethylene (PE) having a density of 0.91 g / cm³ to 0.96 g / cm³. However, it will be understood from this disclosure that the sealing element 300 may be replaced with one made of thermoplastic elastomer (TPE) or one made of silicone-free rubber.

[0129] The airflow passage 400 extends from the air intake 402 formed on the side of the housing 202, through the cartridge 10, through the heating element 116 of the heater assembly 112, and from the heater assembly 112 to the mouthpiece opening 404 formed in the cartridge body 104 at the end of the mouthpiece 106.

[0130] In the diagram of Figure 1, thick arrows are used to schematically represent the direction of airflow into the airflow passage 400 during use of the aerosol generating system, the direction of airflow through it, and the direction of airflow out of it. Although the diagram of Figure 1 schematically shows two separate accesses for air intakes into the airflow passage 400, it will be understood that the air intakes may extend continuously along the perimeter of the housing 202 at the interface between the cartridge body 104 and the housing 202 of the aerosol generating device 200.

[0131] The aerosol generating system 10 is configured so that the user can inhale or draw out the aerosol into their mouth through the mouthpiece opening 404 by using the mouthpiece 106 of the cartridge 100.

[0132] During operation, when the user inhales through the mouthpiece 106, air is drawn in from the air intake 402 through the airflow passage 400, through the heater assembly 112, and reaches the aerosol outlet defined by the mouthpiece opening 404. The control circuit 206 controls the power supply from the battery 204 to the cartridge 100 when the system is operating. The power supplied to the cartridge 100 controls the amount and nature of the vapor generated by the heater assembly 10. The control circuit 206 may include an airflow sensor (not shown), and the control circuit 206 may supply power to the heater assembly 10 when the airflow sensor detects user inhalation. Alternatively, the user may activate the aerosol generation system 10 by pressing a button (not shown). When the user inhales over the mouthpiece 106 of the cartridge 100, the heater assembly 112 is activated, generating vapor, which is drawn into the airflow passing through the heater assembly 112. The vapor is cooled within the cartridge to form an aerosol before reaching the user's mouth through the mouthpiece opening 404.

[0133] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc., are understood to be modified in all cases by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within them, which may or may not be specifically listed herein. Thus, in this context, number A is understood as A ± 10 percent (10%). In this context, number A may be considered to include a numerical value within the general standard error of the measurement of the characteristic modified by number A. In some cases used in the appended claims, number A may deviate by the percentages listed above, provided that the amount of deviation of A does not substantially affect the fundamental and novel characteristics of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within them, which may or may not be specifically listed herein.

Claims

1. A cartridge for an aerosol generation system, A cartridge body having a liquid storage section for holding a liquid aerosol forming substrate, A heater assembly comprising a heating element for vaporizing the liquid aerosol-forming substrate, and a porous ceramic body for transporting the liquid aerosol-forming substrate from the liquid storage portion to the heating element, A sealing element configured to provide a sealing engagement between the porous ceramic body and the cartridge body, a) Cotton or polyethylene (PE), b) Thermoplastic elastomer (TPE), c) A cartridge comprising a sealing element containing at least 50 weight percent of one of the silicone-free rubbers.

2. The cartridge according to claim 1, wherein the sealing element comprises 95% by weight or more of one of cotton or polyethylene (PE), thermoplastic elastomer (TPE), and silicone-free rubber.

3. The aforementioned polyethylene is 0.91 g / cm³ 3 ~0.96 g / cm³ 3 The cartridge according to claim 1, having the density of [a certain value].

4. The thermoplastic elastomer is 0.9 g / cm³ 3 ~1.5 g / cm 3 The cartridge according to claim 1, having the density of [a certain value].

5. The cartridge according to claim 1, wherein the silicone-free rubber is selected from a list consisting of natural polyisoprene (cis-1,4-polyisoprene natural rubber and trans-1,4-polyisoprene galvanic tapper percha), synthetic polyisoprene, polybutadiene rubber, chloroprene rubber, polychloroprene, neoprene, butyl rubber, halogenated butyl rubber, styrene-butadiene rubber, nitrile rubber, and hydrogenated nitrile rubber.

6. The cartridge according to claim 1, wherein the silicone-free rubber is selected from the list consisting of ethylene propylene rubber, ethylene propylene diene rubber, epichlorohydrin rubber, polyacrylic rubber, fluoroelastomer, perfluoroelastomer, polyether block amide, chlorosulfonated polyethylene, and ethylene vinyl acetate.

7. The cartridge according to claim 1, wherein the silicone-free rubber is selected from the list consisting of resilin, elastin, polysulfide rubber, elastorphine, and poly(dichlorophosphazene).

8. The cartridge according to claim 1, wherein the porous ceramic body extends from the liquid absorption surface of the porous ceramic body to the liquid heating surface of the porous ceramic body, and the heating element is provided on the liquid heating surface.

9. The cartridge according to claim 1, wherein the porous ceramic body extends from the liquid absorption surface of the porous ceramic body to the liquid heating surface of the porous ceramic body, and the heating element is at least partially embedded within the porous ceramic body.

10. The cartridge according to any one of claims 1 to 9, wherein the sealing element includes a cup-shaped body configured to be placed on the porous ceramic body.

11. The cartridge according to claim 10, wherein the cup-shaped body has an opening at one end and defines an internal cavity for receiving at least a portion of the porous ceramic body.

12. The cartridge according to claim 11, wherein the overall shape and volume of the internal cavity substantially match the overall shape and volume of the porous ceramic body.

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