Cartridge for an aerosol generating system, an aerosol generating system including a cartridge, and a method for manufacturing a heater assembly and a cartridge for an aerosol generating system - Patents.com

Abstract

A cartridge for an aerosol generating device is disclosed, comprising a housing that accommodates an aerosol-forming substrate and a heater element that includes a fluid-permeable heater portion and an electrical contact portion. The heater portion and the electrical contact portion may be integrally formed from a single heater sheet. The heater portion may be enclosed within the housing and positioned to heat the aerosol-forming substrate, and the electrical contact portion may extend outside the housing. The electrical contact portion may be bent to form an electrical contact pad. A method for manufacturing such a cartridge is also disclosed.

Description

[Technical field]

[0001] The present invention relates to aerosol generation systems, and in particular to aerosol generation systems that produce an aerosol for inhalation by a user. [Background technology]

[0002] One type of aerosol generating system is an electrically heated smoking system. Electrically heated smoking systems generate an aerosol for inhalation by a user. Electrically heated smoking systems come in a variety of forms. One popular type of electrical smoking system is the e-cigarette, which vaporizes a liquid substrate to form an aerosol. One recent design uses a mesh heating element, through which the vaporized substrate passes. Examples are described in WO 2015 / 117702.

[0003] Typically, these aerosol generating systems comprise a main unit that comprises a reusable power source and a cartridge that contains the liquid substrate and a heater. The cartridge is typically a single-use consumable unit that is discarded after the liquid substrate has been depleted.

[0004] However, the consumable units are often complex and expensive to manufacture. In one widely used design, the heater is a coil of wire wrapped around a capillary material. This is not simple to manufacture. The cartridges are also difficult to recycle.

[0005] It would be desirable to produce cartridges that are simple to manufacture and assemble. It would be desirable to produce cartridges that are simple to recycle. It would be desirable to produce cartridges that are compact and robust in use.

[0006] The invention is defined in the independent claims. Advantageous features are set out in the dependent claims. Summary of the Invention

[0007] According to the present disclosure, a cartridge for an aerosol generating device may comprise a housing containing an aerosol-forming substrate and a heater element comprising a fluid-permeable heater portion and an electrical contact portion. The heater portion and the electrical contact portion may be integrally formed from a single heater sheet. The heater portion may be enclosed within the housing and positioned to heat the aerosol-forming substrate, and the electrical contact portion may extend outside the housing.

[0008] The use of a single element to provide both a heater portion for heating the aerosol-forming substrate and a contact portion that can be connected to an external power source simplifies manufacturing and minimizes the number of separate components that need to be assembled in particular. The heater portion is held within the housing and is therefore protected by the housing. The heater portion is typically delicate. The heater portion requires a relatively high electrical resistance compared to the contact portion and therefore a finer, i.e. more easily damaged, structure. The heater portion may comprise, for example, a thin filament. Holding the heater portion within the housing provides a robust cartridge. The user is also protected from the heater portion by the housing during use. The electrical contact portion extends outside the housing to allow for the provision of electrical energy from an external power source to the heater portion.

[0009] The heater portion may be planar and may lie in a first plane. Planar heater portions are simple to manufacture and simple to assemble into a cartridge. As used herein, planar means extending parallel to a Euclidean plane. A planar heater portion extends in two dimensions along a surface, typically substantially more than in a third dimension. In particular, the dimensions of a planar heating element in two dimensions within its surface may be at least five times greater than the dimensions in the third dimension perpendicular to the surface.

[0010] The aerosol-forming substrate may be in a condensed form at room temperature. The aerosol-forming substrate may be a liquid at room temperature. The aerosol-forming substrate may be a solid at room temperature or may be in another condensed form such as a gel at room temperature.

[0011] As used herein and below, the term "aerosol-forming substrate" refers to a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating or burning the aerosol-forming substrate.

[0012] As used herein and below, the term "aerosol" refers to a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets in a gas. Aerosols may be visible or invisible. Aerosols may include not only vapors of substances that are normally liquids or solids at room temperature, but also solid particles or liquid droplets, or a combination of solid particles and liquid droplets.

[0013] Heating of the aerosol-forming substrate by the heating element may release the volatile compound from the aerosol-forming substrate as a vapor. The vapor may then cool within the housing to form an aerosol.

[0014] The heating element may be configured to operate by resistive heating, in other words, the heating element may be configured to generate heat when an electric current is passed through the heating element.

[0015] The electrical contact portion may be bent out of the first plane, forming an out-of-plane section, which allows for simple forming of the electrical contact into a robust configuration and provides convenient and reliable electrical contact. The electrical contact portion may be bent such that a portion of the electrical portion that extends outside the housing is parallel to an exterior surface of the housing. The electrical contact portion may be bent such that a portion of the electrical portion that extends outside the housing conforms to an exterior surface of the housing.

[0016] The heater element may be formed from a material that has some resilience. In particular, the electrical contact portions may be resilient. This may allow the electrical contact portions to be forced into contact with an external power source, thereby ensuring a reliable electrical connection. Advantageously, the heater element is also malleable, allowing it to be bent into a desired configuration.

[0017] In operation, the heater portion may be heated as a result of an electrical current passing through the heater portion. The heater element may comprise a first electrical contact portion and a second electrical contact portion positioned on an opposite side of the heater portion such that an electrical current passing from the first electrical contact portion to the second electrical contact portion passes through the heater portion.

[0018] The heater portion may include one or more openings or slots through the heater sheet, which may provide increased electrical resistance compared to the electrical contact portion(s). The one or more openings or slots may include a spiral, zigzag, or grid pattern.

[0019] The heater sheet may be a foil. As used herein, foil refers to a metal sheet. The heater sheet may include a metal sheet. The heater sheet may include, for example, stainless steel, copper, aluminum, silver, or gold. The heater sheet may include an electrically insulating sheet having relatively conductive inclusions. The heater sheet may include a fabric. The heater sheet may include a ceramic material. The heater sheet may include carbon fiber.

[0020] The heater portion may include a mesh, array or pattern formed from a plurality of conductive filaments. The conductive filaments may define gaps between the filaments, and the gaps may have a width of 10 μm to 100 μm. The filaments preferably create capillary action within the gaps such that, in use, the liquid aerosol-forming substrate to be vaporized is drawn into the gaps, increasing the contact area between the heater portion and the liquid.

[0021] The conductive filaments may form a mesh with a size of 160-600 mesh US (±10%) (i.e., 160-600 filaments per inch (±10%)). The gap width is preferably 150 μm-25 μm. The percentage of the open area of ​​the mesh, which is the ratio of the gap area to the total area of ​​the mesh, may be 1%-80%. The conductive filaments consist of an array of filaments arranged parallel to each other.

[0022] The conductive filaments may have a width of 10 μm to 100 μm, preferably 10 μm to 50 μm, and more preferably 20 μm to 40 μm.

[0023] The area of ​​the mesh, array, or pattern of conductive filaments is between 10 and 100 mm 2 , for example, 10 to 30 mm 2 , or, for example, 30 to 100 mm 2 The mesh, array, or pattern of conductive filaments may, for example, be rectangular and have dimensions of 10 mm by 5 mm.

[0024] Preferably, the electrical resistance of the mesh, array, or pattern of conductive filaments in the heater portion is between 0.3 and 4 ohms, more preferably between 0.3 and 2 ohms, and even more preferably between 0.5 and 1 ohm, or about 0.55 ohms.

[0025] The heater sheet may have a thickness of 0.01 millimeters to 0.5 millimeters, and more preferably has a thickness of 0.02 millimeters to 0.3 millimeters.

[0026] During operation, the heater portion may reach temperatures of 140-240 degrees C. These temperatures allow for the production of dense and stable aerosols without combustion of the aerosol-forming substrate.

[0027] The heater sheet may comprise a generally U-shaped planar section including a heater portion including at least a portion of an electrical contact portion and a first out-of-plane section and a second out-of-plane section. The first out-of-plane section may be connected to a first end of the U-shaped section and the second out-of-plane section may be connected to a second end of the U-shaped section. The first out-of-plane section and the second out-of-plane section may comprise electrical contact pads. The out-of-plane sections may be located outside the housing. The U-shaped sections may be located substantially within the housing.

[0028] The electrical contact portion(s) may be coated or plated with a conductive material such as gold, silver, copper, or zinc, which may provide improved contact resistance with an external power source, and may also provide greater strength to the electrical contact portion(s).

[0029] The heater portions may be coated or plated with a conductive material such as gold, silver, copper, or zinc. This may provide improved resistance to corrosion. This may also provide improved thermal conductivity (for faster heating and faster cooling). This may also reduce electrical resistance if required for a given pattern of heater filaments.

[0030] In some embodiments, the heater portion has a first side in contact with the aerosol-forming substrate in the housing and a second side in contact with an airflow passage extending through the cartridge. The heater portion is advantageously vapor permeable. With this arrangement, vapor generated from the aerosol-forming substrate as a result of heating of the heater portion can pass through the heater portion into the airflow passage.

[0031] The aerosol-forming substrate may be a liquid at room temperature. The cartridge may comprise a wicking material configured to deliver the liquid aerosol-forming substrate to the heater portion of the heater element.

[0032] The wicking material may have a fibrous or spongy structure. The wicking material preferably comprises a bundle of capillaries. For example, the wicking material may comprise a plurality of fibers or threads, or other fine tubes. The fibers or threads may be generally aligned to transport the liquid to the heater. Alternatively, the wicking material may comprise a spongy or foam-like material. The structure of the wicking material forms a plurality of small holes or tubes through which the liquid can be transported by capillary action. The wicking material may comprise any suitable material or combination of materials. Examples of suitable materials are spongy or foam materials, ceramic or graphite-based materials in the form of fibers or sintered powders, expanded metal or plastic materials, fibrous materials, such as fibrous materials made of spun or extruded fibers (such as cellulose acetate, polyester, or bonded polyolefin, polyethylene, terylene or polypropylene fibers, nylon fibers or ceramics).

[0033] The housing may include only a single wicking material. The housing may contain two or more different wicking materials, with a first wicking material in contact with the heater portion having a higher pyrolysis temperature and a second wicking material in contact with the first wicking material but not with the heating element having a lower pyrolysis temperature. The first wicking material effectively acts as a spacer separating the heater portion from the second capillary material so that the second wicking material is not exposed to temperatures above its pyrolysis temperature. As used herein, "pyrolysis temperature" means the temperature at which a material begins to lose mass by decomposing and generating gaseous by-products. The second wicking material may advantageously occupy a larger volume than the first wicking material and may hold more aerosol-forming substrate than the first wicking material. The second wicking material may have better wicking performance than the first wicking material. The second wicking material may be less expensive or have a higher loading capacity than the first wicking material. The second wicking material may be polypropylene.

[0034] The cartridge may be refillable with the aerosol-forming substrate. A reservoir refill port may be provided in the outer sleeve. The reservoir fill port may be closed by a reservoir cap. The reservoir may have a capacity of approximately 1 mL.

[0035] In some embodiments, the housing comprises an upper housing portion and a lower housing portion. The heater element may be disposed between the upper and lower housing portions. The heater element may advantageously be clamped between the upper and lower housing portions and thus fixed in place relative to other components of the cartridge. Clamping the heater element in place is a relatively simple operation during assembly of the cartridge. The upper and lower housing portions may contact one or more points or areas on the electrical contact portion of the heater element to hold the heater element in place. The heater portion that is to be raised to an elevated temperature may be held out of contact with the upper and lower housing portions.

[0036] The cartridge may further comprise an outer housing in which the upper and lower housings are held. In some embodiments, the outer housing comprises a sleeve into which the upper and lower housing portions are received in an orientation parallel to the plane of the heater portion. This allows for a simple assembly process.

[0037] At least one of the upper and lower housing portions may be formed from a resilient material, such as silicone rubber. The resilient material may be compressed by the outer housing, thereby exerting a clamping force on the heater element. The resilient material may also provide a fluid-tight and air-tight seal with the outer housing.

[0038] The lower housing part may comprise a hole across which the heater part is positioned. This allows the heater part to be kept out of contact with the lower housing part. The hole may form all or part of the liquid reservoir. This also allows the aerosol-forming substrate to be positioned in the hole and heated by the heater part. The aerosol-forming substrate may be heated by conduction by the heater part. The cartridge may comprise a wicking material in the hole in the lower housing part. The wicking material may be configured to deliver the liquid aerosol-forming substrate to the heater part.

[0039] The cartridge may include an airflow passageway extending from a distal end of the cartridge, past the heater portion, to a proximal end of the cartridge. At least a portion of the airflow passageway may be defined between the upper and lower housing portions. This allows for simplified manufacture of the housing components.

[0040] The airflow passage may be substantially straight between the proximal and distal ends of the cartridge, which may reduce the collection of debris in the airflow passage when compared to designs with complex airflow paths.

[0041] The airflow passage may include at least one constriction between the heater portion and the proximal end of the cartridge. The at least one constriction may assist in aerosol formation. One or more filters may be provided in the airflow passage. A filter in the airflow passage may prevent large droplets from exiting the cartridge through the mouthpiece.

[0042] The electrical contact portion may protrude from the distal end of the cartridge. This allows for easy connection of the cartridge to an external power source. A mouthpiece may be provided at the proximal end of the cartridge. The airflow passage may have an outlet within the mouthpiece. The mouthpiece may be configured to allow a user to draw air through the airflow passage from the distal end to the proximal end with a puffing action. A replaceable mouthpiece element may be positioned outside the mouthpiece of the outer housing. The replaceable mouthpiece may be made of a softer material than the outer housing.

[0043] In some embodiments, the cartridge has a substantially prismatic shape, such as a rectangular parallelepiped shape. The cartridge may have a length, a width, and a thickness. The thickness may extend in a direction perpendicular to the first plane and is substantially less than the length or width. This cartridge shape has proven popular with end users. The length may extend in a direction parallel to a line between the proximal and distal ends of the cartridge. The length may be greater than the width of the cartridge. The thickness may be less than or equal to half the length or width of the cartridge. A relatively thin cartridge allows the cartridge to be stored comfortably in a user's pocket.

[0044] The outer sleeve may be formed from a metal or a sturdy plastic material. The upper and lower housing portions may be formed from a heat resistant plastic material. Advantageously, at least one of the upper and lower housing portions may be formed from a resilient material such as silicone rubber.

[0045] The cartridge as described has very few components and is simple to assemble. This has several advantages. The first advantage is good reliability. Having fewer components means there is less interaction between components and less potential for misalignment problems at the interfaces. It also means there are fewer sources of failure.

[0046] A second advantage is reduced cost, both from reduced material costs for a compact cartridge with fewer parts and reduced manufacturing costs associated with simpler tooling and fewer process steps.

[0047] A third advantage is the potential for reduced environmental impact. Cartridges as described use relatively few raw materials. The materials used can be largely recyclable or biodegradable. Also, the cartridges are simple to disassemble, allowing easier recycling and disposal of the separate components.

[0048] A fourth advantage is that the cartridge can be made small in one dimension perpendicular to the plane of the heater portion, which allows the cartridge to be easily stored and transported.

[0049] Also disclosed is an aerosol generation system including a cartridge and a main unit as described above, the main unit including a power source and electrical contacts electrically connected to the power source, the electrical contacts of the main unit may be configured to engage with the electrical contact portion(s) of the cartridge.

[0050] The main unit may comprise a control circuit configured to control the supply of power from the power source to the electrical contacts. The control circuit may comprise a puff sensor configured to detect when a user takes a puff on the system, and in particular on the mouthpiece of the system. The puff sensor may comprise an airflow sensor. The control circuit may include a user interface that allows a user to activate the heater. The user interface may comprise a button or switch.

[0051] The main unit may have a length, a width, and a thickness. The thickness may be less than or equal to half the length or width. The width and thickness of the main unit may match the width and thickness of the cartridge.

[0052] The system may be configured such that power is provided from the power source to the heater portion only while the user is taking a puff. Alternatively, the system may be configured such that power to the heater portion is provided both while the user is taking a puff and between the user's puffs. In some embodiments, more power may be provided to the heater portion during the user's puff than between the user's puffs. During operation, the heater portion may reach a temperature of between 140 and 240 degrees Celsius.

[0053] The main unit may be configured to supply power to the heater element according to a particular heating strategy. The control circuitry may include a puff sensor configured to detect when a user has taken a puff on the system. The control circuitry may be configured to control the supply of power to the heater element dependent on an output from the puff sensor. The control circuitry may be configured to supply power to the heater element following detection of a user puff. The control circuitry may be configured to supply power to the heater element for a predetermined period following detection of each user puff.

[0054] The main unit, and in particular the control circuitry, may be configured to provide a first non-zero power to the heater element between user puffs, or to provide power sufficient to maintain the heater portion at a first temperature or within a first temperature range. The main unit, and in particular the control circuitry, may be configured to provide a second power to the heater element during a user puff, the second power being greater than the first power.

[0055] Providing power to the heater element between user puffs can advantageously increase the volume of aerosol generated by the system. Combined with a heater portion having a relatively large surface area, this allows large volumes of aerosol to be generated in a compact device and at moderate temperatures relative to the heater element.

[0056] The control circuit may comprise a microprocessor, which may be a programmable microprocessor, a microcontroller, or an application specific integrated circuit chip (ASIC) or other electronic circuit capable of providing control. The control circuit may comprise further electronic components. The control circuit may be configured to regulate the supply of power to the heater element. Power may be supplied to the heating element continuously following start-up of the system. Power may be supplied to the heater element in the form of current pulses.

[0057] The system may be an electrically heated smoking system.The system may be a nicotine delivery system.The reservoir portion may contain an aerosol-forming substrate comprising nicotine.

[0058] The system may be a handheld aerosol generating system. The aerosol generating system may have a size comparable to a conventional cigar or cigarette. The smoking system may have a total length of about 30 mm to about 150 mm. The smoking system may have a width of about 10 mm to about 50 mm. The smoking system may have a thickness of about 3 mm to about 10 mm.

[0059] The power source may be a battery, such as a lithium iron phosphate battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows for storage of sufficient energy for one or more smoking experiences. For example, the power source may have a capacity sufficient to allow continuous generation of aerosol for approximately 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 sufficient to allow for a predetermined number of puffs, or discontinuous activation of the heater element.

[0060] Although the system is described as a two-part system consisting of a main unit and a cartridge, it is possible to provide a one-part system in which the cartridge includes a power source such as a battery and control circuitry. In such a system, a separate main unit may not be required.

[0061] Further disclosed is a heater element for an aerosol generation system, the heater element being formed from a single heater sheet and comprising a fluid permeable heater portion and an electrical contact portion connected to the fluid permeable heater portion, the fluid permeable heater portion being planar and lying within a first plane, and the electrical contact portion being bent out of the first plane.

[0062] The heater element may include a first electrical contact portion and a second electrical contact portion positioned on an opposite side of the heater portion such that electrical current passing from the first electrical contact portion to the second electrical contact portion passes through the heater portion.

[0063] The heater portion may include one or more openings or slots through the heater sheet, which may provide areas of increased electrical resistance. The openings or slots may include a spiral, zigzag, or grid pattern.

[0064] The heater sheet may be a foil. The heater sheet may comprise a metal sheet. The heater sheet may comprise, for example, stainless steel, copper, silver, aluminum, or gold. The heater sheet may comprise an electrically insulating sheet having relatively conductive inclusions. The heater sheet may comprise a fabric. The heater sheet may comprise a ceramic material. The heater sheet may comprise carbon fiber.

[0065] The heater sheet may have a thickness of 0.01 millimeters to 0.5 millimeters, and more preferably has a thickness of 0.02 millimeters to 0.3 millimeters.

[0066] The heater sheet may comprise a generally U-shaped planar section including a heater portion including at least a portion of an electrical contact portion and a first out-of-plane section and a second out-of-plane section. The first out-of-plane section may be connected to a first end of the U-shaped section and the second out-of-plane section may be connected to a second end of the U-shaped section. The first out-of-plane section and the second out-of-plane section may comprise electrical contact pads.

[0067] The electrical contact portion(s) may be coated or plated with a conductive material, such as gold. This may provide improved contact resistance with an external power source. This may also provide greater strength to the electrical contact portion(s).

[0068] The heater portions may be coated or plated with a conductive material such as gold, silver, copper, or zinc. This may provide improved resistance to corrosion. This may also provide improved thermal conductivity (for faster heating and faster cooling). This may also reduce electrical resistance if required for a given pattern of heater filaments.

[0069] The heater as described is simple to manufacture and easy to assemble into a finished cartridge or aerosol generating device.

[0070] Also disclosed is a method of manufacturing a heater element for an aerosol generating device, comprising processing a planar sheet to form a heater element having a fluid permeable heater portion and at least one electrical contact portion connected to the heater portion disposed on a first planar surface, and bending the electrical contact portion out of the first plane.

[0071] The planar sheet may be a foil. The planar sheet may comprise a metal sheet. The planar sheet may comprise stainless steel, copper, silver, aluminum, or gold. The planar sheet may comprise an electrically insulating sheet having relatively conductive inclusions. The planar sheet may comprise a fabric. The planar sheet may comprise a ceramic material. The planar sheet may comprise carbon fiber. The planar sheet may comprise a laminate. The laminate may comprise layers formed from different materials.

[0072] The fabrication step may include chemical etching, stamping, or machining. The fabrication step may include printing the conductive tracks onto the planar sheet. The printing step may include laser printing.

[0073] Manufacturing the heater elements in this manner can be accomplished cheaply and reliably in a high volume manufacturing process, and the resulting heater elements can be easily handled in the assembly process of the cartridge or aerosol generating device.

[0074] A method of manufacturing a cartridge for an aerosol generating device is further disclosed, the method including forming a heater element having a fluid permeable heater portion and at least one electrical contact portion connected to the heater portion, and disposing the heater element between an upper housing portion and a lower housing portion, whereby the heater portion is positioned between the upper housing portion and the lower housing portion and the electrical contact portion extends outside the lower housing portion and the upper housing portion.

[0075] This is a simple assembly process for the cartridge, involving relatively few components, which allows for fast, reliable and inexpensive manufacture.

[0076] The forming step may include stamping, machining or etching the planar sheet to form the heater portion of the heater element. The forming step may include printing the conductive tracks onto the planar sheet.

[0077] The heater element may be initially formed such that the heater portion and the at least one electrical contact portion lie in a first plane. The method may further include bending the electrical contact portion out of the first plane.

[0078] The method may further include inserting the upper and lower housing portions and the heater element into the outer housing. The outer housing may be a sleeve. The upper and lower housing portions may be mechanically secured to the outer housing sleeve. For example, the outer housing sleeve and the upper and lower housing portions may be molded to provide a snap fit. The outer housing may compress the upper or lower housing portion, or both the upper and lower housing portions to secure the upper and lower housing portions to the outer housing. The outer housing may compress the upper or lower housing portion, or both the upper and lower housing portions to provide a liquid tight seal.

[0079] The method may include filling a reservoir within the outer housing sleeve with a liquid aerosol-forming substrate.

[0080] The disposing step may include clamping the heater element between the upper housing portion and the lower housing. In this manner, it may not be necessary to provide any additional means for securing the heater element within the cartridge, providing a simple assembly process. The outer housing sleeve may provide a clamping force on the heater element.

[0081] A cartridge for an aerosol generating device is also provided, comprising a housing having upper and lower housing portions, the housing containing an aerosol-forming substrate, and a heater element having a fluid-permeable heater portion and an electrical contact portion, the heater element being held between the upper and lower housing portions, the heater portion being positioned to heat the aerosol-forming substrate, and the electrical contact portion extending outside the housing.

[0082] The housing may include an outer housing, an upper housing portion and a lower housing portion carried within the outer housing.

[0083] At least one of the upper and lower housing portions may be formed from a resilient material, such as silicone rubber. The resilient material may be compressed by the outer housing. This may provide a clamping force on the heater element to hold the heater element. This may also provide a fluid-tight seal between the outer housing and the upper and lower housing portions.

[0084] The liquid aerosol-forming substrate may be held within the outer housing. The outer housing may be a sleeve. The upper housing portion, or the lower housing portion, or both the upper and lower housing portions, optionally together with the outer housing, may define a liquid reservoir in which the liquid is held. The lower housing portion may include a hole across which the heater portion is positioned. A wicking material may be provided within the hole in the lower housing portion. The wicking material may transport the liquid from the reservoir to the heater portion. This has the advantage of delivering a constant amount of liquid to the heater portion.

[0085] The cartridge may include an airflow passage extending from a distal end of the cartridge, past the heater portion, to a proximal end of the cartridge. The aerosol or vapor may be drawn out of the cartridge through the airflow passage. At least a portion of the airflow passage is defined between the upper and lower housings. This allows the upper and lower housing portions to be formed with relatively simple shapes that do not require complex molding processes and tools.

[0086] The airflow passage may be substantially straight between the proximal and distal ends of the cartridge.The airflow passage may comprise at least one constriction between the heater portion and the proximal end of the cartridge.

[0087] One or more filters may be provided within the airflow passageway. A filter within the airflow passageway may prevent large droplets from exiting the cartridge through the mouthpiece.

[0088] The electrical contact portion may protrude from a distal end of the cartridge.

[0089] A mouthpiece may be provided at a proximal end of the cartridge. A replaceable mouthpiece element may be positioned outside the mouthpiece of the outer housing. The replaceable mouthpiece may be made from a softer material than the outer housing.

[0090] The cartridge may have a substantially prismatic shape. The cartridge may have a rectangular parallelepiped shape. The cartridge may have a length, a width, and a thickness, the thickness extending perpendicular to the first plane and being substantially less than the length or width. The thickness may be less than or equal to half the length or width of the cartridge. As previously mentioned, this shape of cartridge has proven popular with consumers.

[0091] In all the embodiments described, the aerosol-forming substrate is a substrate capable of releasing a volatile compound capable of forming an aerosol. The volatile compound may be released by heating the aerosol-forming substrate.

[0092] The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise nicotine. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds that are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco-containing material. The aerosol-forming substrate may comprise a homogenised plant-derived material. The aerosol-forming substrate may comprise a homogenised tobacco material. The aerosol-forming substrate may comprise at least one aerosol former. The aerosol former is any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol in use and is substantially resistant to thermal decomposition at the operating temperature of operation of the system. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). Preferred aerosol formers are polyhydric alcohols or mixtures thereof (such as triethylene glycol, 1,3-butanediol, and most preferably glycerin). The aerosol-forming substrate may contain other additives and ingredients, such as flavorants and water.

[0093] The cartridge as described has very few components and is simple to assemble. This has several advantages. The first advantage is good reliability. Having fewer components means there is less interaction between components and less potential for misalignment problems at the interfaces. It also means there are fewer sources of failure.

[0094] A second advantage is reduced cost, both from reduced material costs for a compact cartridge with fewer parts and reduced manufacturing costs associated with simpler tooling and fewer process steps.

[0095] A third advantage is the potential for reduced environmental impact. Cartridges as described use relatively few raw materials. The materials used can be largely recyclable or biodegradable. Also, the cartridges are simple to disassemble, allowing for easy recycling and disposal of the separate components.

[0096] A fourth advantage is that the cartridge can be made small in one dimension perpendicular to the plane of the heater portion, which allows the cartridge to be easily stored and transported.

[0097] It will be apparent that features or elements described with respect to one example or embodiment may also be applied to the other described examples or embodiments. For example, the same wicking material and the same aerosol-forming substrate may be used in each embodiment. Similarly, the same main unit may be used with the different cartridges described.

[0098] Provisions setting out desirable characteristics

[0099] 1. A cartridge for an aerosol generating device, comprising: a housing for containing an aerosol-forming substrate; a heater element comprising a fluid permeable heater portion and an electrical contact portion, the heater portion and the electrical contact portion being integrally formed from a single heater sheet; A cartridge, the heater portion being enclosed within the housing and positioned to heat the aerosol-forming substrate, and the electrical contact portion extending outside the housing.

[0100] 2. The cartridge of claim 1, wherein the heater portion is planar and lies in a first plane.

[0101] 3. The cartridge of claim 2, wherein the electrical contact portion is bent out of the first plane.

[0102] 4. A cartridge described in any one of paragraphs 1 to 3, wherein the heater element comprises a first electrical contact portion and a second electrical contact portion positioned on opposite sides of the heater portion such that current flowing from the first electrical contact portion to the second electrical contact portion passes through the heater portion.

[0103] 5. The cartridge of any one of paragraphs 1 to 4, wherein the heater portion comprises one or more openings or slots through the heater sheet.

[0104] 6. The cartridge of paragraph 5, wherein the one or more openings or slots comprise a spiral, zigzag pattern, or a grid pattern.

[0105] 7. A cartridge according to any one of paragraphs 1 to 6, wherein the sheet has a thickness of 0.01 mm to 0.5 mm, more preferably 0.02 mm to 0.3 mm.

[0106] 8. A cartridge described in any one of paragraphs 1 to 7, wherein the electrical contact portion(s) are coated or plated with a conductive material such as gold.

[0107] 9. A cartridge described in any one of items 1 to 8, wherein the heater portion has a first side in contact with the aerosol-forming substrate in the housing and a second side in contact with an airflow passage extending through the cartridge.

[0108] 10. The cartridge according to any one of items 1 to 9, wherein the aerosol-forming substrate is liquid at room temperature.

[0109] 11. A cartridge as described in paragraph 10, comprising a wicking material configured to deliver a liquid aerosol-forming substrate to a heater portion of a heater element.

[0110] 12. A cartridge as described in any one of claims 1 to 11, wherein the housing comprises an upper housing portion and a lower housing portion, and the heater sheet is disposed between the upper and lower housing portions.

[0111] 13. The cartridge of claim 12, further comprising an outer housing in which the upper and lower housings are retained.

[0112] 14. A cartridge as described in paragraph 13, wherein the outer housing comprises a sleeve into which the upper and lower housing portions are received in an orientation parallel to the plane of the heater portion.

[0113] 15. The cartridge of claim 12, 13, or 14, wherein at least one of the upper and lower housing portions is formed from a resilient material, such as silicone rubber.

[0114] 16. A cartridge as described in paragraphs 12-15, wherein the lower housing portion includes a hole and the heater portion is positioned across the hole.

[0115] 17. A cartridge as described in paragraph 16, comprising a wicking material in the bore of the lower housing portion.

[0116] 18. A cartridge described in any one of paragraphs 1 to 17, comprising an airflow passage extending from the distal end of the cartridge, past the heater portion, to the proximal end of the cartridge.

[0117] 19. A cartridge described in any one of paragraphs 12 to 17, comprising an airflow passage extending from the distal end of the cartridge, past the heater portion, to the proximal end of the cartridge, at least a portion of the airflow passage being defined between the upper housing portion and the lower housing portion.

[0118] 20. A cartridge as described in paragraph 18 or paragraph 19, wherein the airflow passage is substantially straight between the proximal and distal ends of the cartridge.

[0119] 21. The cartridge of paragraph 18, 19, or 20, wherein the airflow passage comprises at least one constriction between the heater portion and the proximal end of the cartridge.

[0120] 22. A cartridge according to any one of paragraphs 1 to 21, wherein the electrical contact portion protrudes from a distal end of the cartridge.

[0121] 23. A cartridge according to any one of paragraphs 1 to 22, wherein a mouthpiece is provided at the proximal end of the cartridge.

[0122] 24. The cartridge according to any one of items 1 to 23, wherein the cartridge has a substantially rectangular parallelepiped shape.

[0123] 25. A cartridge described in any one of paragraphs 1 to 24, having a length, width, and thickness extending in a direction perpendicular to the first plane and being substantially less than the length or width.

[0124] 26. A cartridge as described in paragraph 25, having a thickness that is less than half the length or width of the cartridge.

[0125] 27. The cartridge of paragraph 25 or 26, wherein the length of the cartridge extends between the proximal and distal ends of the cartridge and is greater than the width of the cartridge.

[0126] 28. An aerosol generation system comprising a cartridge described in any one of items 1 to 27, and a main unit comprising a power source and electrical contacts electrically connected to the power source and configured to engage with an electrical contact portion(s) of the cartridge.

[0127] 29. An aerosol generation system as described in paragraph 28, wherein the main unit comprises a control circuit configured to control the supply of power from the power source to the electrical contacts.

[0128] 30. An aerosol generating system as described in paragraph 28 or paragraph 29, wherein the main unit has a length, a width, and a thickness, the thickness being less than half the length or width.

[0129] 31. A heater element for an aerosol generating system, the heater element being formed from a single heater sheet and comprising a fluid permeable heater portion and an electrical contact portion connected to the fluid permeable heater portion, the fluid permeable heater portion being planar and positioned within a first plane, and the electrical contact portion being bent out of the first plane.

[0130] 32. A heater element as described in paragraph 31, comprising a first electrical contact portion and a second electrical contact portion positioned on opposite sides of the heater portion such that current flowing from the first electrical contact portion to the second electrical contact portion passes through the heater portion.

[0131] 33. A heater element as described in paragraph 31 or 32, wherein the heater portion comprises one or more openings or slots through the heater sheet.

[0132] 34. A heater element as described in paragraph 33, wherein the openings or slots have a spiral, zigzag pattern, or grid pattern.

[0133] 35. A heater element as described in any one of paragraphs 31 to 34, wherein the sheet has a thickness of 0.01 millimeters to 0.5 millimeters, more preferably 0.02 millimeters to 0.3 millimeters.

[0134] 36. A heater element as described in any one of paragraphs 31 to 35, wherein the electrical contact portion(s) are coated or plated with a conductive material such as gold.

[0135] 37. A method for manufacturing a heater element for an aerosol generating device, comprising: processing the planar sheet to form a heater element having a fluid permeable heater portion and at least one electrical contact portion connected to the heater portion disposed in a first plane; bending the electrical contact portion out of the first plane.

[0136] 38. The method of claim 37, wherein the forming step includes stamping, machining, or etching a planar sheet to form a heater portion of the heater element.

[0137] 39. A method for manufacturing a cartridge for an aerosol generating device, comprising: forming a heater element having a fluid permeable heater portion and at least one electrical contact portion connected to the heater portion; and disposing a heater element between the upper and lower housing portions, whereby the heater portion is located between the upper and lower housing portions and the electrical contact portion extends outside the lower and upper housing portions.

[0138] 40. The method of claim 39, wherein the forming step includes stamping, machining, or etching a planar sheet to form the heater portion of the heater element.

[0139] 41. The method of claim 39 or 40, wherein the heater element is initially formed such that the heater portion and at least one electrical contact portion lie within a first plane, and the method further comprises bending the electrical contact portion out of the first plane.

[0140] 42. The method of any one of paragraphs 39-41, further comprising inserting the upper and lower housing portions and the heater element into an outer housing.

[0141] 43. A method according to any one of paragraphs 39 to 42, comprising filling a reservoir within the outer housing with an aerosol-forming substrate.

[0142] 44. A cartridge for an aerosol generating device, comprising: a housing having an upper housing portion and a lower housing portion, the housing containing the aerosol-forming substrate; a heater element comprising a fluid permeable heater portion and an electrical contact portion; A cartridge in which a heater element is clamped between upper and lower housing portions and the heater portion is positioned to heat an aerosol-forming substrate, and the electrical contact portion extends outside the housing.

[0143] 45. The cartridge of paragraph 44, wherein the housing comprises an outer housing, an upper housing portion retained within the outer housing, and a lower housing portion.

[0144] 46. ​​A cartridge as described in paragraph 44 or 45, wherein at least one of the upper and lower housing portions is formed from a resilient material, such as silicone rubber.

[0145] 47. A cartridge as described in paragraph 44, 45, or 46, wherein the lower housing portion includes a hole and the heater portion is positioned across the hole.

[0146] 48. A cartridge as described in paragraph 47, comprising a wicking material in the bore of the lower housing portion.

[0147] 49. A cartridge described in any of paragraphs 1 to 48, comprising an airflow passage extending from the distal end of the cartridge, past the heater portion, to the proximal end of the cartridge.

[0148] 50. The cartridge of paragraph 49, wherein at least a portion of the airflow passage is defined between the upper housing and the lower housing.

[0149] 51. A cartridge as described in paragraph 49 or paragraph 50, wherein the airflow passage is substantially straight between the proximal and distal ends of the cartridge.

[0150] 52. A cartridge as described in paragraph 49, paragraph 50, or paragraph 51, wherein the airflow passage comprises at least one constriction between the heater portion and the proximal end of the cartridge.

[0151] 53. A cartridge described in any one of paragraphs 44 to 52, wherein the electrical contact portion protrudes from the distal end of the cartridge.

[0152] 54. A cartridge according to any one of paragraphs 44 to 53, wherein a mouthpiece is provided at the proximal end of the cartridge.

[0153] 55. A cartridge described in any one of items 44 to 54, wherein the cartridge has a substantially rectangular parallelepiped shape.

[0154] 56. A cartridge described in any one of paragraphs 44 to 55, having a length, a width, and a thickness, the thickness extending in a direction perpendicular to the first plane and being substantially smaller than the length or the width.

[0155] 57. A cartridge as described in paragraph 56, the thickness of which is less than half the length or width of the cartridge.

[0156] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0157] [Figure 1A] FIG. 1A is a schematic side view of an aerosol generation system including a disposable cartridge. [Figure 1B] FIG. 1B is a schematic top view of the aerosol generation system of FIG. 1A. [Figure 2A] FIG. 2A is a diagram of the components of a disposable cartridge. [Figure 2B] FIG. 2B shows the components of FIG. 2A with the heater bent into its completed configuration. [Diagram 3] FIG. 3 shows a bottom view of a portion of the cartridge of FIG. 2A. [Figure 4] FIG. 4 is a perspective view of another disposable cartridge. [Diagram 5] FIG. 5 is a flow chart illustrating the cartridge assembly process. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0158] 1A and 1B illustrate aerosol generating systems in schematic form. The aerosol generating system is a handheld smoking system configured to generate an aerosol for inhalation by a user. In particular, the system illustrated in 1A and 1B is a smoking system that generates an aerosol containing nicotine and flavor compounds. 1A is a schematic side view. 1B is a schematic top view.

[0159] The system of Figures 1A and 1B comprises two parts: a main unit 10 and a cartridge 20. In use, the cartridge 20 is attached to the main unit 10.

[0160] The main unit 10 includes a device housing 18 which holds a rechargeable battery 12 and electrical control circuitry 14. The rechargeable battery 12 is a lithium iron phosphate battery. The control circuitry 14 includes a programmable microprocessor and an airflow sensor.

[0161] The cartridge 20 includes an outer housing 34, also called an outer sleeve, which attaches to the main unit 18. In this embodiment, the cartridge is held on the main unit by a magnetic connection.

[0162] Within the outer sleeve of the cartridge are upper and lower housing portions 39 and 38. The upper and lower housing portions, together with the outer sleeve, define a reservoir 30 for the aerosol-forming substrate and an airflow passage 22 through the cartridge. A heater element 32 is held between the upper and lower housing portions. A fluid permeable heater portion 36 of the heater element 32 is positioned between the reservoir and the airflow passage 22. This will be described in more detail with reference to Figures 2A and 2B.

[0163] The heater element 32 may be a resistive heating element. The heater element 32 is formed from a single sheet, in this embodiment, stainless steel foil. As best seen in FIG. 1B, the heater element 32 includes a heater portion 36 positioned between two contact portions 35 and 37. The heater portion 36 has a number of slots etched therethrough, leaving a spiral pattern of heater filament connecting the two contact portions 35, 37. The heater portion filament has a significantly higher electrical resistance than the contact portions, so that when an electrical current is passed through the heater portion filament, the heater portion heats up significantly.

[0164] Contact portions 35, 37 extend from either side of the heater portion to a location external to the cartridge. In particular, the section of each of the contact portions 35, 37 that is external to the cartridge housing portion is bent to provide an electrical contact pad for connection to a corresponding electrical contact 15, 17 in the main unit. The electrical contacts 15, 17 in the main unit are connected to the battery 12 through the control circuit 14. Power is provided from the battery 12 to the heater element under the control of the control circuit, as will be described.

[0165] The cartridge holds an aerosol-forming substrate in a reservoir 30. In this example, the aerosol-forming substrate is a liquid mixture at room temperature and includes nicotine, flavor, an aerosol former (such as glycerol or propylene glycol), and water. The reservoir is defined between the lower housing portion and the outer sleeve. A hole is formed in the lower housing portion that forms part of the reservoir. A heater portion of the heater element extends across the hole and separates the hole from the airflow passage 22. Capillary material 33 is provided in the hole in the lower housing portion and is arranged to facilitate delivery of the aerosol-forming substrate to the heating element regardless of the orientation of the system relative to gravity.

[0166] In this example, a portion of the airflow passage is through the cartridge 20 and a portion of the airflow passage is through the main unit 10. An airflow sensor contained within the control circuit is positioned to detect airflow through the portion of the airflow passage within the main unit. The airflow passage extends from the air inlet 16 to an air outlet 28. The air outlet 28 is at the mouthpiece end of the cartridge. When a user draws on the mouthpiece end of the cartridge, air is drawn from the air inlet 16 through the airflow passage 22 to the air outlet 28.

[0167] The airflow passage 22 is defined, at least in part, between the upper and lower housing portions. The lower housing portion 38 is formed from silicone rubber that is compressed between the outer sleeve and the upper housing, which is made from a more rigid material. In this embodiment, the upper housing portion is formed from Tritan™. Advantageously, all housing elements can be made from a biodegradable or compostable plastic. The compression of the lower housing portion provides a liquid-tight seal of the reservoir. This also provides an air-tight seal of the airflow passage.

[0168] The heater portion 36 of the heater element 32 is positioned within the airflow channel 22. The heater portion is generally planar with one side in fluid communication (e.g., direct or indirect contact) with the liquid in the reservoir 30 and the opposite side in fluid communication (e.g., direct or indirect contact) with air passing through the airflow channel. In operation, a liquid aerosol-forming substrate heated by the heater element is vaporized to form a vapor. The vapor can pass through the heater portion and into the airflow channel.

[0169] In operation, the system may be activated by a user pressing a button (not shown) on the main unit. The control circuitry then provides power to the heater element when airflow through the airflow channel is detected by the flow sensor. In this embodiment, a consistent amount of power is provided to the heater element each time a user puff is detected. This results in heating of the heater portion, which in turn generates vapor in the airflow channel, as described. The vapor is entrained in the air flowing through the airflow channel and is cooled to form an aerosol before exiting the system through the air outlet 26.

[0170] Figures 2A and 2B show an embodiment of a cartridge consistent with the system illustrated in Figures 1A and 1B. Figure 2A shows the cartridge components in an exploded assembly form with the heater element in an unbent state. Figure 2B shows the cartridge components in an exploded assembly form with the contact portions of the heater element 32 bent to form electrical contact pads.

[0171] From FIG. 2A it can be seen that the heater element 32 is clamped between the upper housing portion 39 and the lower housing portion 38 and does not require further fastening. The upper housing portion includes a protrusion 42 that snaps into an opening 44 on the outer sleeve 34 to secure the upper and lower housing portions to the outer sleeve 34. The outer sleeve is transparent and allows the inner tube to be seen, which forms the mouthpiece end of the airflow passage 22. The inner tube is an integrally molded part of the outer sleeve. The outer sleeve, upper housing portion, and lower housing portion are all molded components. The wicking material 33 fits into a hole in the lower housing portion 38.

[0172] In FIG. 2A, the heater element 32 is planar and unbent. The heater element has a U-shape. FIG. 2B illustrates the heater element in its final form. The free ends of the U-shape, corresponding to the section of the electrical contact portion furthest from the heater portion, are bent to form two electrical contact pads 50, 52. The two electrical contact pads are positioned relative to each other on opposite sides of the airflow passage 22. The heater element is bent such that the electrical contact pads extend perpendicular to the plane of the remaining portion of the heater element. The electrical contact pads are fitted near the outer surface of the cartridge formed by the upper and lower housing portions. In this embodiment, the electrical contact portions are each bent twice, once to 90 degrees and then to 180 degrees, such that the electrical contact pads extend outside substantially the entire thickness of the cartridge.

[0173] FIG. 3 shows the spiral design of the heater portion of the heater element in more detail. FIG. 3 is a bottom view of the cartridge of FIG. 2A with the outer sleeve 34 and wicking material shown as transparent. The spiral heater filaments of the heater portion 36 can be clearly seen. Vaporized aerosol-forming substrate can pass between the filaments and into the airflow channel. In this example, the filament thickness and width are approximately 0.1 mm, and the spacing between the filaments is approximately 0.1 mm. However, foil thicknesses as low as 0.01 mm may be used for the heater portion. Electrical contact pads 50, 52 are shown extending just beyond the lower housing portion 38.

[0174] Figure 4 is a perspective view of another embodiment of a cartridge. The embodiment of Figure 4 is similar to the embodiments of Figures 2A, 2B, and 3, except that the heater portion is in the form of a grid or mesh instead of a spiral pattern.

[0175] In Figure 4, the outer sleeve 34 and upper housing portion 39 are shown as transparent so that the heater portion 56 can be seen. The heater portion 56 extends across the airflow channel 22 above the hole in the lower housing portion 38. The inner tube 23 in the outer sleeve 34 which forms the mouthpiece end of the airflow channel can also be seen.

[0176] 2A and 2B, the heater element is clamped between upper and lower housing portions. The portions of the heater element that are external to the cartridge housing are bent to form electrical contact pads 50, 52. In this embodiment, the electrical contact pads are positioned on opposite sides of the airflow channel as in the previous embodiment.

[0177] The cartridges described each include only five components: an outer sleeve, an upper housing portion, a lower housing portion, a heater element, and a wicking material. The components can be made from recyclable or biodegradable materials and can simply break down after use for recycling and disposal.

[0178] An exemplary manufacturing and assembly process for a cartridge of the type shown in Figures 1 to 4 will now be described with reference to Figure 5. Figure 5 is a flow chart showing the steps of the manufacturing process.

[0179] In a first step 500, a planar sheet of material for the heater element is processed to form the heater portion and electrical contact portions. This processing step may include stamping, chemical etching, laser cutting, or machining of a foil or sheet material of suitable conductive and mechanical properties. This processing step may include printing or otherwise depositing a conductive material onto a planar heater substrate. For example, a fluid-permeable membrane may be used as the substrate, and the conductive material that forms the heater portion and electrical contact portions may be deposited onto the membrane.

[0180] Process 500 may also include coating the electrical contact portions, or at least portions of the electrical contact portions, rather than forming the electrical contact pads with a conductive material such as gold, which may reduce the resistance of the electrical contacts.

[0181] At step 510, a planar heater element is disposed between the upper and lower housing portions. The upper and lower housing portions are molded plastic components as previously described. The heater element is positioned such that the heater portion aligns with the hole in the lower housing portion and with the airflow passage defined between the upper and lower housing portions. The heater portion is enclosed within the upper and lower housing portions. Two contact portions of the heater element extend outside the upper and lower housing portions.

[0182] At step 520, the wicking material is inserted into the hole in the lower housing portion. Heater element, upper housing portion, lower housing portion, and wicking material for the atomizer subassembly.

[0183] In step 530, which may be performed in parallel with steps 500-520, the reservoir portion of the outer sleeve is filled with a liquid aerosol-forming substrate.

[0184] At step 540, the atomizer subassembly is inserted into the filled outer sleeve. As described, a simple snap fit or other mechanical interlock can be used to secure the atomizer subassembly to the outer sleeve. The lower housing portion is compressed by the outer sleeve to provide a liquid-tight seal for the reservoir and an air-tight seal for the airflow channel.

[0185] In step 550, the exposed contact portions of the heater elements are bent to form electrical contact pads that extend parallel to the surfaces of the upper and lower housing portions. It will be apparent that step 550 can be performed at any stage after step 500; it does not have to be performed after step 540.

[0186] As an alternative to, or in addition to, step 530, filling the outer sleeve, the wicking material can be dipped into the liquid or gel aerosol-forming substrate and then the wicking material can be inserted into the hole in the lower housing portion.

[0187] The manufacturing and assembly process illustrated in Figure 5 is simple to implement. It requires only the assembly of five components and does not require any fastening elements such as screws or any adhesive. The heater element is very simply fixed within the cartridge. The heater element being planar also simplifies handling.

Claims

1. A cartridge for an aerosol generating device, comprising: a housing for containing an aerosol-forming substrate, the housing comprising an upper housing portion and a lower housing portion; a heater element comprising a fluid permeable heater portion and an electrical contact portion, said heater portion and said electrical contact portion being integrally formed from a single heater sheet; the heater portion is enclosed within the housing and positioned to heat the aerosol-forming substrate, and the electrical contact portion extends outside the housing; The cartridge further comprises an outer housing in which the upper and lower housing portions are retained, the outer housing comprising a sleeve into which the upper and lower housing portions are received, whereby the outer housing compresses the upper and lower housing portions together to provide a seal therebetween.

2. The cartridge of claim 1 , wherein the heater portion is planar and lies in a first plane.

3. The cartridge of claim 2 , wherein the electrical contact portions are bent out of the first plane.

4. A cartridge as described in any one of claims 2 or 3, wherein the upper housing portion and the lower housing portion are received within the sleeve in a direction parallel to the first plane.

5. 5. The cartridge of claim 1, wherein the heater element comprises a first electrical contact portion and a second electrical contact portion positioned on opposite sides of the heater portion such that electrical current passing from the first electrical contact portion to the second electrical contact portion passes through the heater portion.

6. A cartridge according to any preceding claim, wherein the heater portion comprises one or more openings or slots through the heater sheet.

7. 7. A cartridge according to any one of claims 1 to 6, wherein the heater portion has a first side in contact with the aerosol-forming substrate within the housing and a second side in contact with an airflow passage extending through the cartridge.

8. A cartridge according to any preceding claim, wherein the heater sheet is clamped between the upper and lower housing parts.

9. 9. The cartridge of claim 8, wherein the outer housing compresses the upper and lower housing portions to clamp the heater element between the upper and lower housing portions.

10. A cartridge according to any preceding claim, wherein at least one of the upper and lower housing parts is formed from a resilient material, such as silicone rubber.

11. An aerosol generation system comprising a cartridge according to any one of claims 1 to 10, and a main unit comprising a power source and electrical contacts electrically connected to the power source and configured to engage with the electrical contact portion(s) of the cartridge.

12. 1. A method of manufacturing a cartridge for an aerosol generating device, comprising the steps of: forming a heater element having a fluid permeable heater portion and at least one electrical contact portion from a single heater sheet; disposing the heater element between an upper housing portion and a lower housing portion, whereby the heater portion is disposed between the upper housing portion and the lower housing portion and the electrical contact portion extends outside the lower housing portion and the upper housing portion; receiving the upper and lower housing portions within a sleeve of an outer housing whereby the outer housing compresses the upper and lower housing portions together to provide a seal therebetween.

13. forming said heater element by processing a planar sheet such that said fluid permeable heater portion and said at least one electrical contact portion lie in a first plane; and bending the electrical contact portion out of the first plane.

14. 14. The method of claim 13, wherein the processing step comprises stamping, machining, or etching a planar sheet to form the heater portion of the heater element.

15. A cartridge for an aerosol generating device, comprising: a housing having an upper housing portion and a lower housing portion, the housing containing the aerosol-forming substrate; a heater element including a fluid permeable heater portion and an electrical contact portion integrally formed from a single heater sheet; the heater element is held between the upper and lower housing portions and positioned to heat the aerosol-forming substrate, and the electrical contact portion extends outside the housing; The cartridge further comprises an outer housing in which the upper and lower housing portions are retained, the outer housing comprising a sleeve into which the upper and lower housing portions are received, whereby the outer housing compresses the upper and lower housing portions together to provide a seal therebetween.

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