Aerosol generating system and cartridge for aerosol generating system with reduced liquid leakage

Abstract

A cartridge for an aerosol generation system, comprising: a housing defining a storage section for containing a liquid aerosol-forming substrate; a heater comprising a heating element and a porous body, wherein the heating element is positioned on the heating surface of the porous body and the porous body is configured to transport the liquid aerosol-forming substrate to the heating element; a heater holder (130) supporting the heater within the housing and having one or more first sealing ribs (118) on its outer surface for engaging the housing and sealing the storage section; and a plurality of channels (108) formed between the outer surface of the heater holder and the housing on the opposite side of the first sealing ribs from the storage section.

Description

Technical Field

[0001] The present disclosure relates to a cartridge for an aerosol generating system and an aerosol generating system. Specifically, the present disclosure relates to a cartridge for an aerosol generating system and an aerosol generating system including an arrangement for holding a liquid aerosol forming substrate and reducing liquid leakage.

Background Art

[0002] Aerosol generating systems that vaporize a liquid aerosol forming substrate to generate an aerosol for user inhalation are known in the art. An aerosol generating system typically includes a heater for heating the liquid aerosol forming substrate. The liquid aerosol forming substrate is heated by the heater and vaporized to form a vapor. The vapor is cooled and condensed to form an aerosol, which is then inhaled by the user. Such aerosol generating systems are typically portable and include a power source for supplying current to the heater and a reservoir for holding a supply of the liquid aerosol forming substrate. Some aerosol generating systems include an aerosol generating device and a cartridge configured for use with the device. When an aerosol generating system includes an aerosol generating device and a cartridge, the reservoir for the liquid aerosol forming substrate forms part of the cartridge.

[0003] The liquid aerosol-forming substrate needs to allow passage from the storage unit to the heater, and then from the heater in the form of vapor, into the airflow channels within the system or cartridge. The heater is typically held within the system or cartridge in a heater holder structure. The heater holder structure may be used to seal the liquid storage unit and to allow the liquid to pass from the storage unit to the heater. This may require additional sealing components to ensure that the liquid cannot leak between the heater holder structure and the housing of the liquid storage unit. Specifically, manufacturing tolerances may mean that small gaps may exist between the heater holder structure and the housing, even if they are designed to provide an interference fit. Furthermore, when the pressure within the liquid storage unit changes, or when atmospheric pressure changes, the liquid may be drawn out of the housing or out of the porous body through any gaps between the heater holder and the housing. [Overview of the project] [Problems that the invention aims to solve]

[0004] It is desirable to provide an aerosol generating system and cartridges for this type of aerosol generating system that are simple and inexpensive to manufacture, while also preventing or reducing leakage of liquid from the system or cartridge before vaporization. [Means for solving the problem]

[0005] According to a first aspect of this disclosure, a cartridge for an aerosol generating system is provided. The cartridge is The cartridge may include a housing that defines a storage section for containing a liquid aerosol-forming substrate. The cartridge may also include a heater. The heater may include a heating element and a porous body. The heating element may be positioned on the heating surface of the porous body. The porous body may be configured to transport the liquid aerosol-forming substrate to the heating element. The cartridge may also include a heater holder. The heater holder may support the heater within the housing. The heater holder may optionally have one or more first sealing ribs on its outer surface that engage with the housing and seal the storage section. The cartridge may have a plurality of channels formed between the outer surface of the heater holder and the housing. The plurality of channels may be on the opposite side of the storage section from the first sealing ribs.

[0006] Multiple channels formed between the outer surface of the heater holder and the housing are advantageous in that they retain liquid that has passed through one or more first sealing ribs. Multiple channels formed between the outer surface of the heater holder and the housing are advantageous in that they trap liquid that has passed through one or more first sealing ribs. Multiple channels formed between the outer surface of the heater holder and the housing are advantageous in that they retain or trap liquid that has escaped from the porous body. In this way, the possibility of liquid leaking from the cartridge in an undesirable manner and reaching the user or the external environment is reduced or mitigated.

[0007] Multiple channels may be formed by one or more protrusions formed on the outer surface of the heater holder. Multiple channels may be formed by one or more protrusions formed on the inner surface of the housing. Multiple channels may be formed by one or more protrusions formed on the outer surface of the heater holder and one or more protrusions formed on the inner surface of the housing. Advantageously, no additional components are required to form the multiple channels.

[0008] Advantageously, each of the multiple channels has dimensions that allow a meniscus of liquid aerosol-forming substrate to form within the channel. Each of the multiple channels may have a width of 0.5 mm to 2 mm, more preferably 0.5 mm to 1 mm. Each of the multiple channels may have a depth of 0.5 mm to 2 mm, more preferably 0.5 mm to 1 mm. Advantageously, the liquid aerosol-forming substrate adheres to one or more walls of the multiple channels, reducing the tendency for the liquid aerosol-forming substrate to flow through the multiple channels. The materials of one or more walls may be selected for their adhesive properties.

[0009] Multiple channels may be meandering channels. Multiple channels may be labyrinthine channels. Given a given available surface area for channels, meandering channels or labyrinthine channels provide longer path lengths within the channels than straight channels or aligned channels. By providing longer path lengths within the channels, a larger volume of liquid can be retained within the channels, thus reducing larger amounts of liquid leakage from the storage area or porous body.

[0010] Advantageously, multiple channels are interconnected channels. Given a given available surface area, multiple interconnected channels can provide a larger volume for holding liquid than unconnected channels. Multiple interconnected channels may also provide multiple potential entry points for liquid into the interconnected channels. However, it is possible to provide two or more separate channel structures that are not interconnected.

[0011] Multiple channels may be arranged in multiple different patterns or layouts. In one embodiment, the multiple channels comprise three or more transverse channels and multiple longitudinal channels, each transverse channel being connected to an adjacent transverse channel by one or more longitudinal channels, and each longitudinal channel connecting only two transverse channels. The transverse channels may extend in a transverse direction perpendicular to the longitudinal direction. This arrangement provides multiple interconnected meandering channels.

[0012] The multiple channels may comprise a first transverse channel, a second transverse channel, and a third transverse channel, the second transverse channel being positioned between the first and third transverse channels, and each longitudinal channel connecting the first transverse channel to the second transverse channel being transversely offset from each longitudinal channel connecting the second transverse channel to the third transverse channel. This arrangement provides multiple interconnected meandering channels.

[0013] It is not essential that the liquid channels are aligned in the transverse and longitudinal directions. Some or all of the channels can be arranged to extend diagonally or along more complex curved paths.

[0014] The heater holder may be configured to fit into or partially into the housing. One or more first sealing ribs may engage with the inner surface of the housing. One or more first sealing ribs may extend around the outer circumference of the heater holder. One or more first sealing ribs may engage with the inner surface of the housing around the inner circumference of the housing. Multiple channels may be formed between the inner surface of the housing and the outer surface of the heater holder.

[0015] One or more of the transverse channels may, advantageously, extend around the outer circumference of the heater holder. However, the channels may extend in any direction across the outer surface of the heater holder.

[0016] The heater holder may be configured such that it is pushed into the housing in the longitudinal direction during cartridge assembly. The longitudinal direction may be perpendicular to the transverse direction.

[0017] The cartridge may be configured to engage with a power supply unit. The power supply unit may include a DC power source such as a battery. The power supply unit may include a control circuit. The cartridge may be configured to engage with the power supply unit in the longitudinal direction. The cartridge may have a connection end for connecting to the power supply unit and a mouthpiece end opposite the connection end. The connection end and the mouthpiece end may be separated along the longitudinal axis.

[0018] The heater holder may have one or more second sealing ribs on the opposite side of the channel from the first sealing rib, the second sealing ribs engaging with the housing. One or more second sealing ribs may engage with the inner surface of the housing. One or more second sealing ribs may extend around the outer circumference of the heater holder. One or more second sealing ribs may engage with the inner surface of the housing around the inner circumference of the housing.

[0019] Liquid that has passed through one or more first sealing ribs or leaked out of the porous body into multiple channels may be further retained by one or more second sealing ribs.

[0020] The heater holder may include one or more liquid passages extending from the storage section into the porous body. This allows the liquid from the storage section to enter the porous body, which can be vaporized by the heating element.

[0021] The heater holder may include an airflow channel extending from the heated surface of the porous body to an air outlet. The air outlet may be positioned toward the mouthpiece end of the cartridge. The airflow channel may extend along its long axis. The airflow channel may be within or between one or more liquid passages. The airflow channel may extend around the porous body.

[0022] The heater holder may contain an elastomer material. The heater holder may be formed from an elastomer material. The heater holder may be formed entirely from an elastomer material. Preferably, the heater holder contains a thermoplastic elastomer having a Shore A hardness of 60 to 80.

[0023] Preferably, the material of the heater holder has a Shore A hardness of 60 to 80. More preferably, the material of the heater holder has a Shore A hardness of 65 to 75. In a particularly preferred embodiment, the material of the heater holder has a Shore A hardness of 70.

[0024] The term "Shore A hardness" as used herein 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 particular indenter penetrates a sample of the material under specific conditions of force and time. For this purpose, the sample is placed on a hard, flat surface. The indenter 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.

[0025] The heater holder may be formed from two or more materials. The two or more materials may be molded together to form the heater holder. For example, the first sealing rib and the second sealing rib can be formed from a material that is softer than the main body of the heater holder. One or more protrusions on the heater holder may be part of the main body of the heater holder.

[0026] The porous body may be a porous ceramic body. The porous body may include a porous ceramic body or a porous glass body. In other words, the porous body may be a body including porous ceramic, and the porous ceramic has a plurality of pores, and at least a part of the plurality of pores are interconnected. The porous body may be a body including porous glass, and the porous glass has a plurality of pores, and at least a part of the plurality of pores are interconnected.

[0027] The heating element may be an electric heating element. For example, the heating element may be a heating element with electrical resistance. The heating element may be made from any suitable conductive material. Suitable materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide, etc.), carbon, graphite, metals, alloys, and composite materials made from ceramic materials and metal materials. In a preferred embodiment, the electric heating element may include one or more of nickel chromium (NiCr) and titanium zirconium (TiZr).

[0028] The heating element may have any suitable shape or form. Examples of suitable shapes and forms of the heating element include, but are not limited to, strips, flakes, filaments, wires, meshes, spiral coils, fibers, or cloth.

[0029] The heating element may be located on the heating surface of the porous body and may be bonded to the heating surface of the porous body.

[0030] The heating element may be a metal heating element such as a metal heating track.

[0031] The metal track may contain a silver-palladium (Ag-Pd) alloy or a ferrosilicon (Fe-Si) alloy.

[0032] The heater may be positioned so that its heating surface faces the mouthpiece end of the cartridge. Alternatively, the heater may be positioned so that its heating surface faces the connection end of the cartridge. The heater may have two or more heating surfaces. The heater may have two or more heating elements.

[0033] Advantageously, the heater holder is configured to expose the heating surface to the airflow channel. This allows the vapor generated by the heater to be entrained in the airflow, which can then condense to form an aerosol.

[0034] The heater may have electrical contacts at both ends of the heater element. Advantageously, the heater holder is configured to expose the electrical contacts, allowing connection of the electrical contacts to a power source.

[0035] Advantageously, the housing is formed from a housing material. The cartridge housing may be formed from a durable material. The housing may be formed from a liquid-impermeable material. Preferably, the housing material has a Shore A hardness greater than the Shore A hardness of the heater holder. More preferably, the housing material has a Shore A hardness greater than 80. In a particularly preferred embodiment, the heater holder material has a Shore A hardness of 85. The housing may be formed from a moldable plastic material such as polypropylene (PP) or polyethylene terephthalate (PET). The housing material may be polyetheretherketone (PEEK) or Tritan.

[0036] In another embodiment, this disclosure also, The first aspect includes a cartridge as described, The present invention provides an aerosol generation system comprising a power supply unit configured to supply power to a heating element.

[0037] The power supply unit may be equipped with a DC power source such as a battery. The power supply unit may be equipped with a control circuit. The control circuit may regulate the supply of electrical energy to the heater.

[0038] The cartridge may be configured to engage with the power supply unit in the longitudinal direction. The cartridge may have a connection end for connecting to the power supply unit and a mouthpiece end opposite the connection end.

[0039] In a further embodiment, the disclosure provides an aerosol generating system comprising a housing, the housing defining a storage section containing a liquid aerosol-forming substrate. The aerosol generating system may include a heater. The heater may comprise a heating element and a porous body. The heating element may be positioned on the heating surface of the porous body. The porous body may be configured to transport the liquid aerosol-forming substrate to the heating element. The system may also include a heater holder, the heater holder supporting the heater within the housing. The heater holder may have one or more first sealing ribs on its outer surface that engage with the housing and seal the storage section. The aerosol generating system may also include a plurality of channels formed between the outer surface of the heater holder and the housing. The plurality of channels may be located on the opposite side of the first sealing ribs from the storage section.

[0040] The aerosol generation system may be a single-component system that is discarded once the liquid aerosol-forming substrate is used up.

[0041] In all aspects of this disclosure, the aerosol generating system may be a handheld aerosol generating system. The aerosol generating system may be a handheld aerosol generating system configured to allow a user to draw an aerosol through a first air outlet by sucking on a mouthpiece. The aerosol generating system may have a size comparable to a conventional cigar or cigarette. The aerosol generating system may have an overall length of about 25 mm to about 150 mm. The aerosol generating system may have an outer diameter of about 5 mm to about 30 mm.

[0042] In all embodiments of this disclosure, the power source may be a DC power source. The power source may be a battery. The battery may be a lithium-based battery, such as a lithium cobalt battery, 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.

[0043] As used herein, the term “aerosol” is used to describe the dispersion of solid particles, or droplets, or combinations of solid particles and droplets, in a gas. Aerosols may be visible or invisible. Aerosols may include not only vapors of substances that are normally liquid or solid at room temperature, but also solid particles or droplets, or combinations of solid particles and droplets.

[0044] As used herein, the term “liquid aerosol-forming substrate” is used to describe a liquid substrate having the ability to release volatile compounds that may form aerosols. Such volatile compounds may be released by heating the liquid aerosol-forming substrate. The liquid aerosol-forming substrate may contain one or more aerosol-forming compounds. The aerosol-forming compounds are any suitable known compounds or mixtures of compounds that facilitate the formation of a high-density and stable aerosol when used and are substantially resistant to thermal decomposition at the operating temperature of the system. Examples of suitable aerosol-forming compounds include glycerin and propylene glycol. Suitable aerosol-forming compounds 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 contain water, solvents, ethanol, plant extracts, and natural or artificial flavors. 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% (for example, about 2%).

[0045] As used herein, "aerosol generating system" means a system that generates an aerosol from one or more liquid aerosol-forming substrates.

[0046] As used herein, the term “heat-generating element” is used to describe a heat-generating component and a component that transfers thermal energy to a liquid aerosol-forming substrate. Naturally, the heat-generating element may be located directly on or indirectly on the porous material. Naturally, the heat-generating element may be formed integrally with the porous material.

[0047] As used herein, the term “porous material” is used to describe a component having multiple pores, at least some of which are interconnected. A porous material is configured to contain a liquid within its multiple pores. The porous material of a heater assembly according to a first aspect of the present invention includes a porous ceramic material or a porous glass material. The porous material may be a porous ceramic material or a porous glass material.

[0048] As used herein, the term "heated surface" refers to the surface of the porous material closest to the heating element. The heated surface of the porous material may be in contact with the heating element.

[0049] The present invention is defined in the claims. However, 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, forms, or aspects described herein.

[0050] Example 1. A cartridge for an aerosol generation system, A housing comprising a housing that defines a storage section for containing a liquid aerosol forming substrate, A heater comprising a heating element and a porous body, wherein the heating element is positioned on the heating surface of the porous body, and the porous body is configured to transport a liquid aerosol forming substrate to the heating element, A heater holder comprising one or more first sealing ribs on its outer surface that support a heater within a housing and engage with the housing to seal the storage portion, A cartridge comprising a plurality of channels formed between the outer surface of the heater holder and the housing on the opposite side of the first sealing rib relative to the storage section. Example 2. The cartridge according to Example 1, wherein multiple channels are formed by one or more protrusions formed on the outer surface of the heater holder. Example 3. The cartridge according to Example 1, wherein multiple channels are formed by one or more protrusions formed on the inner surface of the housing. Example 4. The cartridge according to Example 1, wherein multiple channels are formed by one or more protrusions formed on the outer surface of the heater holder and one or more protrusions formed on the inner surface of the housing. Example 5. A cartridge according to any one of Examples 1 to 4, wherein each of the multiple channels has dimensions that allow a meniscus of liquid aerosol-forming substrate to form within the channel. Example 6. A cartridge according to any one of Examples 1 to 5, wherein the multiple channels are meandering channels or labyrinthine channels. Example 7. A cartridge according to any one of Examples 1 to 6, wherein multiple channels are interconnected channels. Example 8. A cartridge according to any one of Examples 1 to 7, wherein the multiple channels comprise three or more transverse channels and multiple longitudinal channels, each transverse channel being connected to an adjacent transverse channel by one or more longitudinal channels, and each longitudinal channel being connected to only two transverse channels. Example 9. A cartridge according to any one of Examples 1 to 8, wherein the channel comprises a first transverse channel, a second transverse channel, and a third transverse channel, the second transverse channel being positioned between the first transverse channel and the third transverse channel, and each longitudinal channel connecting the first transverse channel to the second transverse channel being transversely offset from each longitudinal channel connecting the second transverse channel to the third transverse channel. Example 10. The cartridge according to any one of Examples 1 to 9, wherein the heater holder is configured to fit into or partially into the housing. Example 11. A cartridge according to any one of Examples 1 to 10, wherein one or more first sealing ribs engage with the inner surface of the housing. Example 12. A cartridge according to any one of Examples 1 to 11, wherein one or more first sealing ribs extend around the outer circumference of the heater holder. Example 13. A cartridge according to any one of Examples 1 to 12, wherein one or more first sealing ribs engage with the inner surface of the housing around the inner circumference of the housing. Example 14. A cartridge according to any one of Examples 1 to 13, wherein multiple channels are formed between the inner surface of the housing and the outer surface of the heater holder. Example 15. The cartridge according to Example 8 or Example 9, wherein one or more of the transverse channels extend around the outer circumference of the heater holder. Example 16. A cartridge according to any one of Examples 1 to 15, wherein the heater holder is configured such that it is pushed into the housing in the longitudinal direction during cartridge assembly. Example 17. A cartridge according to any one of Examples 1 to 16, wherein the cartridge is configured to engage with a power supply unit. Example 18. A cartridge according to any one of Examples 1 to 17, wherein the power supply unit comprises a power source such as a battery and a control circuit. Example 19. The cartridge according to any one of Examples 1 to 18, wherein the heater holder comprises one or more second sealing ribs on the opposite side of the channel from the first sealing rib, and the second sealing ribs engage with the housing. Example 20. The cartridge according to Example 19, wherein one or more second sealing ribs engage with the inner surface of the housing. Example 21. The cartridge according to Example 19 or Example 20, wherein one or more second sealing ribs extend around the outer circumference of the heater holder. Example 22. The cartridge according to Example 19, Example 20, or Example 21, wherein one or more second sealing ribs engage with the inner surface of the housing around the inner circumference of the housing. Example 23. A cartridge according to any one of Examples 1 to 22, wherein the heater holder comprises one or more liquid passages extending from a storage section into a porous body. Example 24. A cartridge according to any one of Examples 1 to 23, wherein the heater holder comprises an airflow channel extending from a porous heating surface to an air outlet. Example 25. A cartridge according to any one of Examples 1 to 24, wherein the heater holder contains an elastomer material. Example 26. A cartridge according to any one of Examples 1 to 25, wherein the heater holder comprises a thermoplastic elastomer having a Shore A hardness of 60 to 80. Example 27. A cartridge according to any one of Examples 1 to 26, wherein the material of the heater holder has a Shore A hardness of 60 to 80, preferably 65 to 75, more preferably 70. Example 28. The cartridge according to any one of Examples 1 to 27, wherein the heater holder is configured to expose the heating surface to the airflow channel. Example 29. A cartridge according to any one of Examples 1 to 28, wherein the heater has electrical contacts at both ends of the heater element, and the heater holder is configured to expose the electrical contacts. Example 30. A cartridge according to any one of Examples 1 to 29, wherein the housing is formed from a housing material having a Shore A hardness greater than that of the heater holder. Example 31. The cartridge according to Example 30, wherein the housing material has a Shore A hardness greater than 80. Example 32. Aerosol generating system, A cartridge according to any one of Examples 1 to 31, An aerosol generating system comprising a power supply unit configured to supply power to a heating element. Example 33. Aerosol generating system, A housing comprising a housing that defines a storage section for containing a liquid aerosol forming substrate, A heater comprising a heating element and a porous body, wherein the heating element is positioned on the heating surface of the porous body, and the porous body is configured to transport a liquid aerosol forming substrate to the heating element, A heater holder comprising one or more first sealing ribs on its outer surface that support a heater within a housing and engage with the housing to seal the storage portion, An aerosol generating system comprising a plurality of channels formed between the outer surface of the heater holder and the housing on the opposite side of the first sealing rib relative to the storage section. Example 34. The aerosol generation system may be a single-component system that is discarded once the liquid aerosol-forming substrate is used up.

[0051] Here, we will further describe the embodiments with reference to the accompanying diagrams. [Brief explanation of the drawing]

[0052] [Figure 1A] Figure 1A shows a schematic cross-sectional view of the aerosol generation system according to this disclosure. [Figure 1B] Figure 1B shows a schematic cross-sectional view of the aerosol generation system shown in Figure 1A, as used in the configuration. [Figure 2] Figure 2 shows a schematic diagram of the heater holder according to this disclosure. [Figure 3] Figure 3 shows a perspective view of the heater assembly according to this disclosure. [Figure 4A] Figure 4A shows a perspective view of the porous body and the heating element. [Figure 4B] Figure 4B shows an alternative perspective view of the porous material in Figure 5A. [Figure 5] Figure 5 shows a schematic diagram of an alternative embodiment according to this disclosure. [Figure 6A] Figure 6A shows a first pattern of protrusions that can be used in embodiments of the present disclosure. [Figure 6B] Figure 6B shows a second pattern of protrusions that can be used in embodiments of the present disclosure. [Modes for carrying out the invention]

[0053] Figure 1A shows a schematic cross-sectional view of the disassembled aerosol generating system 100 according to the present disclosure. The aerosol generating system 100 comprises a cartridge 140 and a power supply unit 150.

[0054] The cartridge comprises a housing 110 and a heater assembly 120. The housing 110 and heater assembly 120 assembled together form a cartridge 140. The cartridge 140 is reversibly connectable to a power supply unit 150 to form an aerosol generating system 100. The cartridge 140 connected to the power supply unit 150 provides the usage configuration of the aerosol generating system shown in Figure 1B. Alternatively, the system 100 may be provided as a single aerosol generating device comprising the housing 110, heater assembly 120, and power supply unit 150 assembled together, rather than as a separable cartridge and power supply unit.

[0055] The housing 110 comprises an outer wall formed from a polymer. Exemplary polymers may be Tritan or polyetheretherketone (PEEK). The outer wall of the housing 110 defines a liquid storage section 116 for containing a liquid aerosol-forming substrate.

[0056] The housing 110 further comprises an airflow passage 112 passing through the storage section 116. The airflow passage 112 extends from the proximal end of the housing 110 toward the distal end of the housing 110. The walls defining the airflow passage 112 are also formed from a polymer or copolymer, such as Tritan. The airflow passage 112 comprises a housing airflow outlet 114. The housing airflow outlet 114 is defined at the proximal end of the airflow passage 112 and at the proximal end of the housing 100. The airflow passage 112 is substantially centrally located within the housing 110.

[0057] Cartridge 140 comprises a heater assembly 120, which comprises a heater holder 130, a porous body 132, and a heating element 134. The porous body 132 and the heating element 134 may together be referred to as the heater. The porous body 132 is a ceramic porous body configured to transport a liquid aerosol-forming substrate to the heating element 134. The porous body 132 comprises a heating surface on which the heating element 134 is positioned and a back surface opposite the heating surface. The heating element 134 is an electrically resistive heating element. The heater is illustrated in more detail in Figures 5A and 5B.

[0058] As shown in Figure 1A, the heater holder 130 includes two liquid channels 123 located on either side of the air outlet 122. The liquid channels extend between the liquid storage section 116 and the porous body 132, delivering the liquid aerosol-forming substrate from the storage section 116 to the porous body 132.

[0059] The heater holder 130 is positioned within the housing 110 and has an interlocking fit with the housing 110. The heater holder 130 has sealing elements 118 (in this case, multiple sealing ribs) provided on its outer surface to seal the storage section 116 by forming a seal with the inner surface of the housing 110. The sealing elements 118 are provided to prevent the liquid aerosol forming substrate from leaking out of the liquid storage section and into the gap between the heater holder 130 and the housing 110.

[0060] The heater holder also includes a plurality of channels 108 formed between the outer surface of the heater holder and the inner surface of the housing, on the opposite side of the sealing element 118 from the storage section 116. The plurality of channels 108 are formed by projections formed on the outer surface of the heater holder 130. If any liquid leaks from the storage section 116 past the sealing element 118 or from the porous body 132 into the gap between the heater holder 130 and the housing 110, the plurality of channels 108 hold the liquid, reducing the risk of leakage from the cartridge 140. This is illustrated more clearly in Figures 2 and 3 and will be described with reference to Figures 2 and 3.

[0061] The heater holder 130 further comprises a first cavity for supporting the porous body 132 and a second cavity that is in fluid communication with the air outlet 122. The air outlet 122 is in fluid communication with the heater holder outlet 127, which is connected to the airflow passage 112.

[0062] The integrated separation element 126 separates the first cavity from the second cavity, and also covers the back surface of the porous body, preventing fluid communication between the back surface of the porous body 132 and the air outlet 122.

[0063] The cartridge 140 further comprises two cartridge electrical contacts 138. The cartridge electrical contacts 138 are configured to be accessible from the bottom surface of the cartridge. Each cartridge electrical contact 138 is further configured to contact either end of a heating element 134, which is illustrated in more detail in Figure 5A. The two cartridge electrical contacts 138 contain copper with a gold coating.

[0064] The two cartridge electrical contacts 138 are located on either side of the central air intake 142, which allows air to enter the cartridge 140 and the heater assembly 120.

[0065] The power supply unit 150 includes a device cavity. The device cavity is defined by the power supply unit 150 and is configured to receive a portion of the cartridge 140 when the cartridge is connected to the power supply unit 150. The cartridge 140 is configured to be reversibly connected to the power supply unit 150 by a snap-fit.

[0066] The power supply unit 150 further comprises device electrical contacts 155 located on the underside of the device cavity. The device electrical contacts 155 are configured to contact the cartridge electrical contacts 145 when the cartridge 140 is connected to the power supply unit 150. The two device electrical contacts 155 include copper with a gold coating. The power supply unit 150 further comprises a control circuit 154. The device electrical contacts 155 are connected to the control circuit 154 via wires. The power supply unit 150 further comprises a power supply 156. The power supply 156 comprises a rechargeable lithium-ion battery that is rechargeable via an electrical connector (not shown) at the distal end of the power supply unit 150. The power supply 156 is connected to the control circuit 154 via wires.

[0067] Figure 1B shows the aerosol generation system 100 in use, with the cartridge 140 connected to the power supply unit 150. During use, the user may reversibly connect the cartridge 140 to the power supply unit 150, or disconnect the cartridge 140 from the power supply unit 150, for example, when there is no liquid aerosol forming substrate in the storage unit 116. The cartridge 140 may also be connected to the power supply unit 150 at its distal end by a snap-fit.

[0068] When the cartridge 140 is connected to the power supply unit 150, a small gap exists between the distal end of the cartridge 140 and the power supply unit 150. During use, air may enter the system air intake 152. The system air intake is in fluid communication with the air intake 142.

[0069] When connected to the power supply unit 150, a portion of the cartridge 140 is housed within the device cavity such that the device electrical contact 155 is in contact with the cartridge electrical contact 138. Thus, a complete electrical path is formed from the device electrical contact 155 to the cartridge electrical contact 138, and then to the heating element 134.

[0070] When in use, the user connects the cartridge 140 to the power unit 150 and starts the system by pressing a button (not shown) located on the side of the power unit 150. The button is connected to the control circuit 154. The control circuit 154 is configured to control the supply of power from the power supply 156 to the heating element 134 via the device electrical contacts 155 and the cartridge electrical contacts 138. When the user presses the button, power is supplied from the power supply 156 to the heating element 134 via the control circuit 154, the device electrical contacts 155, and the cartridge electrical contacts 138, thereby raising the temperature of the heating element 134. The liquid aerosol forming substrate in the storage section 116 is drawn out from the liquid passage 123 in the heater holder 130 to the porous body 132 of the heater assembly 120. The porous body 132 draws the liquid aerosol forming substrate to the heated surface of the ceramic body 132, where the liquid aerosol forming substrate is volatilized by the high-temperature heating element 134.

[0071] When the user inhales from the proximal end of the housing 110, air is drawn through the aerosol generation system 100. Specifically, air is drawn into the system through the system air intake 152 and then through the cartridge air intake 142. The air passes over the heated surface of the porous body 132 and the high-temperature heating element 134, where the volatile aerosol-forming substrate is carried with the air. The volatile aerosol-forming substrate condenses in the airflow through the cartridge 140 to form an aerosol. The aerosol-containing airflow passes through the porous body and proceeds through the air outlet 122. This is drawn into the user's mouth via the airflow passage 112 and the cartridge airflow outlet 114.

[0072] The airflow 172 passes through the cartridge 140 almost perpendicular to the long axis of the system 100. The long axis of the system 100 is substantially parallel to the direction of the airflow from the porous body 132 through the airflow passage 112 to the cartridge airflow outlet 114.

[0073] Figure 2 shows a schematic cross-sectional view of the heater holder 130 of the aerosol generation system shown in Figure 1. The heater holder 130 is made of a thermoplastic elastomer having a Shore A hardness of 70. The heater holder 130 comprises a first cavity 124, a second cavity 128, and a separation element 126 that separates the first cavity 124 from the second cavity 128. The separation element 126 is integrated with the heater holder 130.

[0074] The heater holder 130 includes sealing elements in the form of parallel sealing ribs 118, 119. The sealing ribs 118, 119 are integrated with the outer circumference of the heating holder 130 and extend around the outer circumference of the heating holder 130, and are arranged to engage with the inner surface of another component of the aerosol generating system (such as the housing 110 shown in Figure 1) to seal the liquid storage section. The first sealing rib 118 is arranged to prevent the liquid aerosol forming substrate from leaking out of the liquid storage section and into the gap between the heater holder 130 and the housing 110. The heater holder further includes a second sealing rib 119. The second sealing rib is provided at the end of the heater holder 130 opposite to the first sealing element 118. The second sealing rib provides an additional barrier to liquid leaking out of the cartridge, as well as a barrier to contaminants entering the cartridge.

[0075] Between the first sealing rib 118 and the second sealing rib 119, a plurality of projections 162 are formed on the outer surface of the heater holder. The projections 162 define a plurality of interconnected liquid channels 108. The liquid channels 108 act to hold any liquid that leaks through the first sealing rib 118 or leaks from the porous body into the space between the heater holder and the housing. In this embodiment, it is found that the projection comprises a plurality of parallel projections extending around the periphery of the heater holder. The parallel projections define a plurality of transverse liquid channels between them. Each of the transverse liquid channels is connected to one or two adjacent transverse channels by a channel extending in the longitudinal direction formed between the projections. The projections extend close to the housing of the cartridge such that liquid cannot pass from one transverse channel to the next, except that it is held in the channel and passes through one of the longitudinal channels. It can be seen that each of the longitudinal channels connects only two adjacent transverse channels and is offset transversely from the vertical channel that connects to the next transverse channel. In this way, the liquid traveling through the interconnected channels must traverse a meandering or labyrinthine path, as illustrated by the solid arrows in Figure 2. This increases the path length that the liquid must travel to reach the second sealing rib 119, thereby reducing liquid leakage from the cartridge. The channels formed between the protrusions have dimensions that may result in significant adhesion between the heater holder and any liquid aerosol-forming substrate within the channel, and the formation of a meniscus within the channel. This can reduce the tendency of the liquid aerosol-forming substrate to flow rapidly through the channel structure. The material of the outer surface of the heater holder can also be selected to enhance liquid adhesion.

[0076] As described with reference to Figure 5, some or all of the protrusions defining the liquid channel can instead be formed on the inner surface of the housing.

[0077] The porous body (not shown in Figure 2) is supported by a heater holder 130 within the first cavity 124. A separation element 126, integrated with the heater holder 130, separates the porous body from the air outlet 122 and prevents liquid from leaking into the airflow from the rear surface of the porous body.

[0078] Figure 3 shows a schematic isometric view of the heater assembly according to the present disclosure. The heater assembly 120 comprises a porous body 132 supported by a heater holder 130 within a first cavity 124 of the heater holder 130. The separating element 126 is in contact with the back surface of the porous body 132 and covers the back surface of the porous body 132.

[0079] The heater holder 130 includes a holder outlet 127 that communicates with an air outlet 122 (not shown in Figure 4). The heater holder 130 also includes two liquid passages 123 defined above both sides of the holder outlet 127.

[0080] The liquid passage 123 is defined between the porous body 132 and the liquid storage section of the aerosol generation system. The liquid passage transports the liquid from the liquid storage section to the porous body 132.

[0081] The interconnected liquid channels 108 formed between the protrusions 162 are clearly shown in Figure 3.

[0082] The heater holder has two openings defined through the heater holder on opposing sides of the heater holder 130. The first opening aligns with the third surface of the porous body 132, and the second opening aligns with the fourth surface of the porous body 132. The second opening and the fourth surface of the porous body 132 are on the opposite side of the heater holder 130 and are not visible in Figure 3. When present in the aerosol generating system, portions of the airflow path that are in contact with the third and fourth surfaces of the porous body are also in contact with other elements of the aerosol generating system 100 outside the heater holder 130, through openings aligned with the third and fourth surfaces of the porous body.

[0083] The electrical contact 338 is electrically connected to a heating element (not shown) positioned on the heated surface of the porous body 132.

[0084] When the heater assembly 120 is present in the aerosol generating system 100 during use, the heater holder is positioned inside the housing as shown in Figures 1A and 1B. The portions of the airflow path that are in contact with the third and fourth surfaces of the porous body 132 are also in contact with the inner surface of the housing.

[0085] Figure 4A shows a schematic isometric view of a heater equipped with a porous body and a heating element, and Figure 4B shows a schematic alternative isometric view of the heater.

[0086] The heating element 134 is shown to be disposed on the heating surface below the porous body 132. The heating element has two heating element electrical contacts 135 at both ends of the heating surface 131 of the ceramic body 132. The two heating element electrical contacts 135 are configured to contact the cartridge electrical contacts 138 as described above.

[0087] The heating element 134 further comprises a meandering heating element path 133 extending between two heating element electrical contacts 135. The meandering heating element path 133 is configured to resistively heat as current passes through it. The heating element 134 is a metal track comprising a metal film. The two heating element electrical contacts 135 are formed integrally with the meandering heating element path 133. For example, the heating element 134 can be made of a silver-palladium (Ag-Pd) alloy or a ferrosilicon (Fe-Si) alloy.

[0088] Two liquid feed notches 136 are defined within the porous body 132. Each of the two liquid feed notches 136 is defined within the back surface 137 at both ends of the porous body 132.

[0089] When the porous body 132 is positioned within the heater holder 130, the liquid aerosol-forming substrate flows from the heater holder liquid channel 123 into the corresponding liquid feed notch 136, and then into the porous body 132.

[0090] Figure 5 is a schematic diagram of an alternative embodiment of the present disclosure, in which a projection forming a liquid channel between the heater holder and the housing is part of the inner surface of the housing. In Figure 5, the housing 410 of the cartridge includes a projection 462 on its inner surface 470. The projection 462 defines a plurality of liquid channels. The heater holder 430 supports the heater 139. The heater holder 430 includes a first sealing rib 418 that engages with the inner surface 470 of the housing 410 on the liquid storage side of the projection 462. The heater holder 430 includes a second sealing rib 419 that engages with the inner surface 470 of the housing 410 on the opposite side of the projection 462 to the first sealing rib 418.

[0091] The projection pattern in the embodiment of Figure 5 can take various forms. Figure 6A illustrates one embodiment in which longitudinal channels connecting adjacent transverse channels are aligned with each other. In this case, the liquid may be able to move rapidly through the entire network of channels. This pattern can also be used in the embodiments of Figures 2 and 3.

[0092] Figure 6B illustrates a preferred channel arrangement, as shown in Figures 2 and 3, in which the longitudinal channels connecting adjacent transverse channels are offset from each other. This creates a more complex fluid pathway from one end of the structure to the other.

[0093] In both Figures 6A and 6B, all the liquid channels are interconnected. However, it is possible to arrange protrusions to form two or more separate liquid channel structures that are not interconnected. Furthermore, the channels in Figures 6A and 6B are aligned with the transverse and longitudinal axes of the system. However, this is not mandatory, and some or all of the channels can be arranged to extend diagonally or along more complex curved paths.

Claims

1. A cartridge for an aerosol generation system, A housing comprising a housing that defines a storage section for containing a liquid aerosol forming substrate, A heater comprising a heating element and a porous body, wherein the heating element is positioned on the heating surface of the porous body, and the porous body is configured to transport the liquid aerosol forming substrate to the heating element, A heater holder comprising one or more first sealing ribs on its outer surface that support the heater within the housing and engage with the housing to seal the storage portion, A cartridge comprising the outer surface of the heater holder and a plurality of channels formed between the housing on the opposite side of the first sealing rib relative to the storage portion.

2. The cartridge according to claim 1, wherein the plurality of channels are formed by one or more protrusions formed on the outer surface of the heater holder.

3. The cartridge according to claim 1, wherein the plurality of channels are formed by one or more protrusions formed on the inner surface of the housing.

4. The cartridge according to claim 1, wherein the plurality of channels are formed by one or more protrusions formed on the outer surface of the heater holder and one or more protrusions formed on the inner surface of the housing.

5. The cartridge according to any one of claims 1 to 4, wherein the plurality of channels are meandering channels.

6. The cartridge according to any one of claims 1 to 5, wherein the plurality of channels are interconnected with one another.

7. The cartridge according to any one of claims 1 to 6, wherein the plurality of channels comprises three or more transverse channels and a plurality of longitudinal channels, each of the transverse channels is connected to an adjacent transverse channel by one or more longitudinal channels, and each longitudinal channel connects only two transverse channels.

8. The cartridge according to any one of claims 1 to 7, wherein the channel comprises a first transverse channel, a second transverse channel, and a third transverse channel, the second transverse channel being positioned between the first transverse channel and the third transverse channel, and each longitudinal channel connecting the first transverse channel to the second transverse channel being offset in the transverse direction from each longitudinal channel connecting the second transverse channel to the third transverse channel.

9. The cartridge according to any one of claims 1 to 8, wherein the heater holder comprises one or more second sealing ribs on the opposite side of the channel from the first sealing rib, and the second sealing ribs engage with the housing.

10. The cartridge according to any one of claims 1 to 9, wherein the heater holder comprises a liquid passage extending from the storage section to the porous body.

11. The cartridge according to any one of claims 1 to 10, wherein the heater holder comprises an elastomer material.

12. The cartridge according to any one of claims 1 to 11, wherein the heater holder exposes the heating surface to the airflow channel.

13. The cartridge according to any one of claims 1 to 12, wherein the heater holder exposes an electrical contact fixed to the heating element, or an electrical contact integrated with the heating element.

14. Aerosol generation system, A cartridge according to any one of claims 1 to 13, an aerosol generating system comprising a power supply unit configured to supply power to the heat-generating element.

15. Aerosol generation system, A housing comprising a housing that defines a storage section for containing a liquid aerosol forming substrate, A heater comprising a heating element and a porous body, wherein the heating element is positioned on the heating surface of the porous body, and the porous body is configured to transport the liquid aerosol forming substrate to the heating element, A heater holder comprising one or more first sealing ribs on its outer surface that support the heater within the housing and engage with the housing to seal the storage portion, An aerosol generating system comprising: the outer surface of the heater holder and a plurality of channels formed between the housing on the opposite side of the first sealing rib relative to the storage portion.

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