Resistance-enhanced heating element

Abstract

A heating element (11) for an aerosol generating system is provided, the heating element (11) including a mesh (12). The mesh (12) includes a plurality of first filaments (20) extending in a first direction (21), each of the first filaments (20) including a first end (24) and a second end (26). The mesh (12) also includes a plurality of second filaments (22) extending in a second direction (23), the first direction (21) being perpendicular to the second direction (23). Each of the second filaments (22) includes a third end (28) and a fourth end (30). The second end (26) of the first filament (20) is electrically connected to the third end (28) of the second filament (22).

Description

[Technical Field]

[0001] The present invention relates to a heating element for an aerosol generation system. In particular, the present invention relates to a heating element for an aerosol generation system, the heating element having first and second filaments extending in first and second directions, an end of the first filament electrically connected to an end of the second filament. The present invention also relates to a heater assembly, a cartridge, and an aerosol generation system. [Background technology]

[0002] Handheld, electrically operated aerosol generating devices and systems are known that include a device portion including a battery and control electronics, a portion for housing or receiving a liquid aerosol-forming substrate, and an electrically operated heater for heating the aerosol-forming substrate to generate an aerosol. In some devices, the heater includes a conductive mesh. Electric current can be passed through the mesh to resistively heat the heater, thereby generating an aerosol from the aerosol-forming substrate. A mouthpiece portion is also included, which a user can inhale to draw the aerosol into their mouth.

[0003] It is desirable to increase the electrical resistance of a mesh heater while reducing, minimizing, or eliminating the need to increase the size of the mesh heater. It is desirable to increase the electrical resistance of a mesh heater without changing the material used to form the mesh heater. Summary of the Invention

[0004] According to the present disclosure, there is provided a heating element for an aerosol generating system, the heating element comprising a mesh. The mesh may comprise a plurality of first filaments extending in a first direction. Each of the first filaments may have a first end and a second end. The mesh may comprise a plurality of second filaments extending in a second direction. The first direction may be perpendicular to the second direction. Each of the second filaments may have a third end and a fourth end. The second end of the first filament may be electrically connected to the third end of the second filament.

[0005] According to a first aspect of the present disclosure, a heating element for an aerosol generating system is provided, the heating element comprising a mesh. The mesh comprises a plurality of first filaments extending in a first direction, each of the first filaments having a first end and a second end. The mesh also comprises a plurality of second filaments extending in a second direction, the first direction being perpendicular to the second direction. Each of the second filaments has a third end and a fourth end. The second ends of the first filaments are electrically connected to the third ends of the second filaments.

[0006] Advantageously, electrically connecting the second end of the first filament to the third end of the second filament can increase the path length of electrical current flowing through the mesh. In particular, electrical current through the mesh can flow in a first direction along the length of the first filament and then in a second direction along the length of the second filament. Advantageously, increasing the path length of electrical current through the mesh increases the electrical resistance of the mesh. Advantageously, increasing the electrical resistance of the mesh increases the heat output of the heating element for a given electrical current.

[0007] Preferably, the heating element includes a conductive portion extending between the second end of the first filament and the third end of the second filament. Advantageously, the conductive portion facilitates electrical connection of the second end of the first filament to the third end of the second filament.

[0008] Preferably, the conductive portion electrically connects the second end of each of the first filaments to the third end of each of the second filaments. Preferably, the conductive portion electrically connects the third end of each of the second filaments to the second end of each of the first filaments. Preferably, the conductive portion is a continuous portion of conductive material. For example, the conductive portion may include a continuous region of conductive material to which the second end of each of the first filaments and the third end of each of the second filaments are electrically connected. The second end of the first filament may be soldered to the conductive portion. The third end of the second filament may be soldered to the conductive portion.

[0009] The first filament may include a first material having a first electrical conductivity, the second filament may include a second material having a second electrical conductivity, and the conductive portion may include a third material having a third electrical conductivity, preferably the third electrical conductivity being greater than both the first electrical conductivity and the second electrical conductivity.

[0010] Advantageously, providing the conductive portion with a greater electrical conductivity than the first filament and the second filament facilitates current flow from the first filament to the second filament between the second end of the first filament and the third end of the second filament.

[0011] The first material can be the same as the second material. The first material can be different from the second material.

[0012] Preferably, each of the first material and the second material is about 0.8×10 6 siemens / meter and approximately 1.7 x 10 6 It has an electrical conductivity of siemens / meter.

[0013] Preferably, the third material is about 8×10 6 Siemens / meter ~ approx. 80 x 10 6 It has an electrical conductivity of siemens / meter.

[0014] The mesh may include a plurality of contact points where each first filament overlies or underlies each second filament. Preferably, the first electrical conductivity of the first filaments is greater than the electrical conductivity between each first filament and each second filament at the contact points. Preferably, the second electrical conductivity of the second filaments is greater than the electrical conductivity between each first filament and each second filament at the contact points. Preferably, the third electrical conductivity of the conductive portion is greater than the electrical conductivity between each first filament and each second filament at the contact points.

[0015] The conductive portion may include a metal. The conductive portion may include at least one of copper, zinc, nickel, tin, silver, gold, and platinum. The conductive portion may include at least one of silver, gold, and platinum. The conductive portion may be formed from at least one of silver, gold, and platinum.

[0016] Each of the first filaments may comprise a metal alloy. Examples of suitable alloys include stainless steel, constantan, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation. Preferably, each of the first filaments comprises stainless steel, more preferably 300-series stainless steel, such as AISI 304, 316, 304L, or 316L. In a particularly preferred embodiment, each of the first filaments comprises AISI 304 stainless steel.

[0017] Each of the second filaments may comprise a metal alloy. Examples of suitable alloys include stainless steel, constantan, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, iron-aluminum-based alloys, and iron-manganese-aluminum-based alloys. Timetal® is a registered trademark of Titanium Metals Corporation. Preferably, each of the second filaments comprises stainless steel, more preferably 300-series stainless steel, such as AISI 304, 316, 304L, or 316L. In a particularly preferred embodiment, each of the second filaments comprises AISI 304 stainless steel.

[0018] Each of the first filaments may comprise a different material than each of the second filaments. Preferably, each of the first filaments comprises the same material as each of the second filaments.

[0019] The mesh may be woven or non-woven. Preferably, the mesh is woven.

[0020] The first filaments may extend in a weft direction and the second filaments may extend in a warp direction.The first filaments may extend in a warp direction and the second filaments may extend in a weft direction.

[0021] The mesh may define gaps between the first filaments and the second filaments, and the gaps may have a width of about 10 micrometers to about 100 micrometers. Preferably, the width of the gaps allows capillary action to occur within the gaps, so that the liquid aerosol-forming substrate, which will be vaporized in use, is drawn into the gaps, increasing the contact area between the heating element and the liquid aerosol-forming substrate.

[0022] The first filaments and the second filaments may form a mesh density of about 60 to about 240 filaments per centimeter (±10%). Preferably, the mesh density is about 100 to about 140 filaments per centimeter (±10%). More preferably, the mesh density is approximately 115 filaments per centimeter. The gap width may be about 20 micrometers to about 300 micrometers, preferably about 50 micrometers to about 100 micrometers, and more preferably about 70 micrometers. The open area of ​​the mesh, which is the ratio of the gap area to the total area of ​​the mesh, may be about 40 percent to about 90 percent, preferably about 85 percent to about 80 percent, and more preferably about 82 percent.

[0023] Each of the first filaments and each of the second filaments can have a width or diameter of about 10 micrometers to about 100 micrometers, preferably 10 micrometers to 50 micrometers, more preferably about 12 micrometers to about 25 micrometers, and most preferably approximately 16 micrometers. Each of the first filaments and each of the second filaments can have a round cross-section or a flat cross-section.

[0024] The mesh area can be small, for example, about 50 square millimeters or less, preferably about 25 square millimeters or less, and more preferably approximately 15 square millimeters. Preferably, the mesh area facilitates incorporation of the heating element into a handheld system. Advantageously, sizing the mesh to have an area of ​​about 50 square millimeters or less reduces the total amount of power required to heat the mesh while ensuring sufficient contact of the mesh with the liquid aerosol-forming substrate. The mesh can be square. The mesh can be rectangular. The mesh can be cross-shaped. The mesh can have a maximum length of about 2 millimeters to about 10 millimeters. The mesh can have a maximum width of about 2 millimeters to about 10 millimeters. Preferably, the mesh has a maximum width of about 5 millimeters and a maximum length of about 5 millimeters.

[0025] Preferably, the mesh is substantially planar. Advantageously, a substantially flat mesh can facilitate simple fabrication of heating elements and aerosol generating systems including the heating elements. Geometrically, the term "substantially flat" is used to refer to a mesh that is in the form of a substantially two-dimensional topological manifold. In some embodiments, a substantially flat mesh can extend substantially in two dimensions along a surface rather than in three dimensions. In some embodiments, the dimension of a substantially flat mesh in two dimensions within its surface can be at least five times its dimension in the third dimension perpendicular to the surface. In some embodiments, a substantially flat mesh can define two substantially imaginary parallel flat surfaces. In some embodiments, a substantially flat mesh can be a structure between two substantially imaginary parallel flat surfaces, where the distance between these two imaginary surfaces is substantially less than the extension within the surface. In some embodiments, only one of the two substantially imaginary parallel surfaces can be flat. In some embodiments, a substantially flat mesh can be planar. In other embodiments, a substantially flat mesh can be curved along one or more dimensions, for example, forming a dome or bridge shape.

[0026] According to a second aspect of the present disclosure, there is provided a heater assembly for an aerosol generation system, the heater assembly comprising a heating element according to the first aspect of the present invention, according to any embodiment described herein, the heater assembly also including a first electrical contact electrically connected to a first end of at least one of the first filaments, and a second electrical contact electrically connected to a fourth end of at least one of the second filaments.

[0027] The first and second electrical contacts facilitate the supply of electrical current to and from the heating element. Preferably, the first electrical contact electrically connects the first ends of the first filaments to each other. Preferably, the second electrical contact electrically connects the fourth ends of the second filaments to each other.

[0028] Preferably, the first electrical contact is a continuous portion of conductive material. For example, the first electrical contact may include a continuous region of conductive material to which the first ends of each of the first filaments are electrically connected. The first ends of the first filaments may be soldered to the first electrical contact.

[0029] Preferably, the second electrical contact is a continuous portion of conductive material. For example, the second electrical contact may include a continuous region of conductive material to which the fourth ends of each of the second filaments are electrically connected. The fourth ends of the second filaments may be soldered to the second electrical contact.

[0030] The heater assembly may comprise a substrate having a heating element disposed thereon. Preferably, the substrate defines an opening therethrough, with at least a portion of the heating element covering the opening. Advantageously, the opening may facilitate transfer of the liquid aerosol-forming substrate to the heating element.

[0031] In embodiments where the heating element comprises an electrically conductive portion, the electrically conductive portion is preferably provided on the substrate. In embodiments where the heating element comprises first and second electrical contacts, each of the first and second electrical contacts is preferably provided on the substrate.

[0032] The substrate may comprise any suitable material or combination of materials. The substrate may comprise phenolic paper. The substrate may comprise glass fiber reinforced epoxy resin. The substrate may comprise a plastic or thermoplastic suitable for food or pharmaceutical applications. The substrate may comprise at least one of polypropylene, polyetheretherketone (PEEK), and polyethylene. Preferably, the material is light and not brittle.

[0033] The heater assembly may include at least two electrical terminals for supplying power to the heating element. The heater assembly may include a first electrical terminal and a second electrical terminal. In embodiments in which the heating element includes first and second electrical contacts, preferably the first electrical terminal contacts the first electrical contact and the second electrical terminal contacts the second electrical contact. Each of the electrical terminals may be a spring terminal. Each of the electrical terminals may include brass.

[0034] The heater assembly may further include a heater assembly housing, with the heating element mounted on the heater assembly housing. In embodiments where the heater assembly includes at least two electrical terminals, the at least two electrical terminals may be mounted on the heater assembly housing.

[0035] In embodiments in which the heater assembly includes a substrate, the substrate may be mounted on the heater assembly housing. The substrate may form a part of the heater assembly housing.

[0036] The heater assembly housing may comprise any suitable material or combination of materials. Preferably, the heater assembly housing is formed from a plastic or thermoplastic material suitable for food or pharmaceutical applications. For example, the heater assembly housing may comprise at least one of polypropylene, polyetheretherketone (PEEK), and polyethylene. Preferably, the material is lightweight and not brittle.

[0037] The heater assembly may further include a transport material for transporting the liquid aerosol-forming substrate to the heating element. Preferably, the transport material includes a first end in contact with the mesh of the heating element. The transport material may include a capillary material. The transport material may include a capillary wick. The transport material may include a ceramic. The ceramic may include at least one of aluminum oxide, zirconium oxide, and hydroxyapatite.

[0038] In embodiments where the heater assembly includes a heater assembly housing, at least a portion of the transport material may be received within the heater assembly housing. The transport material may be secured within the heater assembly housing by an interference fit.

[0039] The transport material can be formed by depositing a material directly onto the mesh of the heating element. The transport material can be formed by depositing a ceramic directly onto the mesh of the heating element. The ceramic can include at least one of aluminum oxide, zirconium oxide, and hydroxyapatite.

[0040] According to a third aspect of the present disclosure, there is provided a cartridge for an aerosol generation system, the cartridge including a heater assembly according to the second aspect of the present disclosure, according to any of the embodiments described herein. The cartridge may also include a liquid storage compartment for holding a liquid aerosol-forming substrate.

[0041] The term "aerosol" as used herein 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.

[0042] As used herein, the term "aerosol-forming substrate" refers to a substrate capable of emitting a volatile compound that can form an aerosol. The volatile compound may be emitted by heating or burning the aerosol-forming substrate.

[0043] In embodiments in which the heater assembly includes a heater assembly housing, the heater assembly housing may define at least a portion of the liquid storage compartment.

[0044] The liquid storage compartment may include first and second storage portions in communication with each other. The first storage portion of the liquid storage compartment may be on an opposite side of the heater assembly from the second storage portion of the liquid storage compartment. The liquid aerosol-forming substrate may be held in both the first and second storage portions of the liquid storage compartment.

[0045] Advantageously, the first storage portion of the storage compartment is larger than the second storage portion of the liquid storage compartment. The cartridge may be configured to allow a user to draw from or suck on the cartridge to inhale the aerosol generated by the cartridge. In use, the opening at the mouth end of the cartridge is typically positioned above the heater assembly, and the first storage portion of the storage compartment is positioned between the opening at the mouth end and the heater assembly. Making the first storage portion of the liquid storage compartment larger than the second storage portion of the liquid storage compartment ensures that liquid is delivered from the first storage portion of the liquid storage compartment to the second storage portion of the liquid storage compartment under the influence of gravity.

[0046] The cartridge may have a mouth end through which a user can draw the generated aerosol and a connecting end configured to connect to an aerosol generating device. Preferably, a first side of the heating element faces the mouth end and a second side of the heating element faces the connecting end.

[0047] In embodiments in which the heater assembly includes a transport material, the transport material is preferably in fluid communication with the liquid storage compartment. Preferably, the transport material is in fluid communication with a second storage portion of the liquid storage compartment. Preferably, the second end of the transport material is disposed within the second storage portion of the liquid storage compartment.

[0048] The cartridge may define an enclosed airflow passage from the air inlet, passing through the first side of the heater assembly, to an opening at the mouth end of the cartridge. The enclosed airflow passage may pass through the first storage portion or the second storage portion of the liquid storage compartment. In one embodiment, the airflow passage extends between the first storage portion and the second storage portion of the liquid storage compartment. Additionally, the airflow passage may penetrate the first storage portion of the liquid storage compartment. At least a portion of the first storage portion of the liquid storage compartment may have an annular cross-section, and at least a portion of the airflow passage may extend from the air inlet, through the heater assembly, through the first storage portion of the liquid storage compartment, to the mouth end. At least a portion of the airflow passage may extend from the heater assembly to an opening at the mouth end adjacent the first storage portion of the liquid storage compartment.

[0049] The cartridge may include a retaining material for retaining the liquid aerosol-forming substrate. The retaining material may be in a first storage portion of the liquid storage compartment, a second storage portion of the liquid storage compartment, or both the first and second storage portions of the liquid storage compartment. The retaining material may be a foam, a sponge, or a fiber aggregate. The retaining material may be formed of a polymer or copolymer. The retaining material may be a spun polymer. The liquid aerosol-forming substrate may be released into the retaining material during use. For example, the liquid aerosol-forming substrate may be provided in a capsule.

[0050] The cartridge advantageously contains a liquid aerosol-forming substrate in the liquid storage compartment. The liquid aerosol-forming substrate may comprise nicotine. The nicotine-containing liquid aerosol-forming substrate may be a nicotine salt matrix. The liquid aerosol-forming substrate may comprise a plant-derived material. The liquid aerosol-forming substrate may comprise tobacco. The liquid aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds that are released from the aerosol-forming substrate on heating. The liquid aerosol-forming substrate may comprise a homogenised tobacco material. The liquid aerosol-forming substrate may comprise a non-tobacco-containing material. The liquid aerosol-forming substrate may comprise a homogenised plant-derived material.

[0051] The liquid aerosol-forming substrate may contain one or more aerosol formers. The aerosol former is any suitable, well-known compound or mixture of compounds that facilitates the formation of a dense, stable aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the system. Examples of suitable aerosol formers include glycerin and propylene glycol. Suitable aerosol formers are well-known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (such as dimethyl dodecanedioate and dimethyl tetradecanedioate). The liquid aerosol-forming substrate may contain water, solvents, ethanol, plant extracts, and natural or artificial flavors.

[0052] The liquid aerosol-forming substrate may include nicotine and at least one aerosol former. The aerosol former may be glycerin or propylene glycol. The aerosol former may include both glycerin and propylene glycol. The liquid aerosol-forming substrate may have a nicotine concentration of about 0.5 percent to about 10 percent, for example, about 2 percent.

[0053] The cartridge may include a cartridge housing. The cartridge housing may be formed from a moldable plastic material such as polypropylene (PP) or polyethylene terephthalate (PET). The cartridge housing may form some or all of the walls of one or both portions of the liquid storage compartment. The cartridge housing and the liquid storage compartment may be integrally formed. Alternatively, the liquid storage compartment may be formed separately from the cartridge housing and assembled to the cartridge housing.

[0054] According to a fourth aspect of the present disclosure, there is provided an aerosol generation system comprising the cartridge according to the third aspect of the present disclosure, according to any of the embodiments described herein, the aerosol generation system also comprising an aerosol generator arranged to be removably coupled to the cartridge, the aerosol generator comprising a power source for supplying power to the heating element.

[0055] The aerosol generating device may include an electrical circuit configured to control the supply of power from the power source to the heating element.

[0056] The control circuit may include a microprocessor. The microprocessor may be a programmable microprocessor, a microcontroller, or an application specific integrated chip (ASIC) or other electronic circuit capable of providing control. The control circuit may include additional electronic components. For example, in some embodiments, the control circuit may include a sensor, a switch, or a display element. Power may be supplied to the heating element continuously following activation of the aerosol generating device, or may be supplied intermittently (e.g., with each puff). Power may be supplied to the heating element in the form of current pulses, for example, by pulse width modulation (PWM).

[0057] The power source can be a DC power source. The power source can be a battery. The battery can be a lithium-based battery, such as a lithium-cobalt battery, a lithium-iron-phosphate battery, a lithium-titanate battery, or a lithium polymer battery. The battery can be a nickel-metal hydride battery or a nickel-cadmium battery. The power source can be another form of charge storage device, such as a capacitor. The power source can also be rechargeable and configured for numerous charge-discharge cycles. The power source can have a capacity that allows for storage of sufficient energy for one or more user experiences; for example, the power source can have a capacity sufficient to allow continuous generation of aerosol for a period of approximately six minutes, corresponding to the typical time it takes to smoke a conventional cigarette, or a multiple of six minutes. In another example, the power source can have a capacity sufficient to allow for a predetermined number of puffs or discontinuous activation of the heating element.

[0058] The aerosol generating device may include a device housing. The device housing may be elongated. The device housing may comprise any suitable material or combination of materials. Examples of suitable materials include metals, alloys, plastics, or composites containing one or more of these materials, or thermoplastics suitable for food or pharmaceutical applications, such as polypropylene, polyetheretherketone (PEEK), or polyethylene. Preferably, the material is light and not brittle.

[0059] The aerosol generation system may be a handheld aerosol generation system. The aerosol generation system may be a handheld aerosol generation system configured to allow a user to draw on the mouthpiece and draw the aerosol through an opening in the mouth end. The aerosol generation system may have a size comparable to a conventional cigar or cigarette. The aerosol generation system may have a total length of about 30 millimeters to about 150 millimeters. The aerosol generation system may have an outer diameter of about 5 millimeters to about 30 millimeters. [Example]

[0060] The present invention is defined in the claims. However, the following provides a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0061] Example 1: 1. A heating element for an aerosol generating system, the heating element comprising a mesh, the mesh comprising: a plurality of first filaments extending in a first direction, each first filament including a first end and a second end; a plurality of second filaments extending in a second direction, the first direction being perpendicular to the second direction, each of the second filaments including a third end and a fourth end; A heating element wherein the second end of the first filament is electrically connected to the third end of the second filament. Example 2: 10. The heating element of example 1, further comprising a conductive portion extending between the second end of the first filament and the third end of the second filament. Example 3: 3. The heating element of example 2, wherein the first filament comprises a first material having a first electrical conductivity, the second filament comprises a second material having a second electrical conductivity, and the conductive portion comprises a third material having a third electrical conductivity, the third electrical conductivity being greater than both the first electrical conductivity and the second electrical conductivity. Example 4: 4. The heating element of embodiment 2 or 3, wherein the conductive portion comprises at least one of copper, zinc, nickel, tin, silver, gold, and platinum. Example 5: 4. The heating element of example 2 or 3, wherein the conductive portion comprises at least one of silver, gold, and platinum. Example 6: The heating element of example 2 or 3, wherein the conductive portion is formed from at least one of silver, gold, and platinum. Example 7: The heating element of any of Examples 1-6, wherein each of the first filaments comprises stainless steel. Example 8: The heating element of any of Examples 1 to 7, wherein each of the second filaments comprises stainless steel. Example 9: The heating element according to any one of Examples 1 to 8, wherein the mesh is a woven mesh. Example 10: The heating element of any one of Examples 1 to 9, wherein each of the first filaments has a width or diameter of about 10 micrometers to about 100 micrometers.

[0062] Example 11: The heating element of any one of Examples 1 to 10, wherein each of the first filaments has a width or diameter of about 10 micrometers to about 50 micrometers. Example 12: The heating element of any one of Examples 1 to 11, wherein each of the first filaments has a width or diameter of about 12 micrometers to about 25 micrometers. Example 13: The heating element of any one of Examples 1 to 12, wherein each of the second filaments has a width or diameter of about 10 micrometers to about 100 micrometers. Example 14: The heating element of any one of Examples 1 to 13, wherein each of the second filaments has a width or diameter of about 10 micrometers to about 50 micrometers. Example 15: The heating element of any one of Examples 1 to 14, wherein each of the second filaments has a width or diameter of about 12 micrometers to about 25 micrometers. Example 16: 1. A heater assembly for an aerosol generating system, the heater assembly comprising: The heating element according to any one of Examples 1 to 15, a first electrical contact connected to a first end of at least one of the first filaments; and A heater assembly including a second electrical contact connected to a fourth end of at least one of the second filaments. Example 17: 9. The heater assembly of Example 8, further comprising a base defining an opening therethrough, wherein at least a portion of the heating element covers the opening, and wherein each of the first electrical contact and the second electrical contact is provided on the base. Example 18: 10. The heater assembly of example example 9, further comprising a conductive portion extending between the second end of the first filament and the third end of the second filament. Example 19: The heater assembly of example 10, wherein the conductive portion is provided on a substrate. Example 20: 12. The heater assembly of any of Examples 8-11, further comprising a transport material for transporting the liquid aerosol-forming substrate to the heating element. Example 21: 1. A cartridge for an aerosol generation system, the cartridge comprising: The heater assembly of any one of Examples 8 to 12, and A cartridge comprising a liquid storage compartment for holding a liquid aerosol-forming substrate. Example 22: 1. An aerosol generating system comprising: A cartridge as described in Example 13, and An aerosol generation system comprising an aerosol generator arranged to be removably coupled to a cartridge, the aerosol generator comprising a power source for supplying electrical power to a heating element. The embodiments will now be further described with reference to the following figures: [Brief explanation of the drawings]

[0063] [Figure 1] FIG. 1 is a schematic side view of a heater assembly according to one embodiment of the present disclosure. [Figure 2] FIG. 2 is a schematic top view of the heater assembly of FIG. [Figure 3]FIG. 3 is a schematic cross-sectional side view of an exemplary aerosol generation system including a cartridge and an aerosol generator. [Figure 4] FIG. 4 is a schematic cross-sectional side view of the aerosol generation system of FIG. 3 rotated 90 degrees about the longitudinal axis of the aerosol generation system. DETAILED DESCRIPTION OF THE INVENTION

[0064] 1 and 2, a heater assembly 10 is shown comprising a heating element 11 and a ceramic transport material 14.

[0065] Heating element 11 includes a conductive mesh 12 disposed on a substrate 13. Mesh 12 is woven and includes a plurality of first filaments 20 extending in a first direction 21 and a plurality of second filaments 22 extending in a second direction 23 perpendicular to first direction 21. Each of the first filaments 20 has a first end 24 and a second end 26. Each of the second filaments 22 has a third end 28 and a fourth end 30. Each of the first and second filaments 20, 22 is formed from stainless steel.

[0066] A first electrical contact 32 is disposed on the substrate 13 and electrically connected to the first end 24 of the first filament 20. A second electrical contact 34 is disposed on the substrate 13 and electrically connected to the fourth end 30 of the second filament 22. A conductive portion 36 is disposed on the substrate 13 and electrically connects the second end 26 of the first filament 20 to the third end 28 of the second filament 22. The conductive portion 36 is formed from a material having a higher electrical conductivity than the stainless steel from which the first filament 20 and the second filament 22 are formed. For example, the conductive portion 36 may be formed from brass or copper. During use, a voltage is applied across the first electrical contact 32 and the second electrical contact 34, causing a current to flow through the first filament 20 and the second filament 22 via the conductive portion 36.

[0067] 2 , first electrical contact 32 is connected to the positive terminal of a DC power supply, and second electrical contact 34 is connected to the negative terminal of the DC power supply. As a result, current flows from first electrical contact 32 to conductive portion 36 along first filament 20 and from conductive portion 36 to second electrical contact 34 along second filament 22, as illustrated by dashed line 38. The current flowing through first filament 20 and second filament 22 resistively heats mesh 12. Advantageously, conductive portion 36 facilitates resistive heating along the length of both first filament 20 and second filament 22.

[0068] 2 is exemplary only, and the polarity of the first and second electrical contacts 32, 34 may be reversed. It is also possible for the first and second electrical contacts 32, 34 to be electrically connected to opposite terminals of an AC power source.

[0069] The ceramic transport material 14 is in direct contact with the mesh 12 through the openings 15 in the substrate 13. The ceramic transport material 14 is positioned to transport the liquid aerosol-forming substrate to the mesh 12. A plurality of gaps 16 are defined between the first and second filaments 20, 22 of the mesh 12. During heating, the vaporized aerosol-forming substrate is released from the heater assembly 10 through the gaps 16 to generate an aerosol.

[0070] Figure 3 is a schematic cross-sectional view of one embodiment of an aerosol generation system, and Figure 4 shows the same cross-sectional view of the aerosol generation system rotated 90 degrees about its longitudinal axis.

[0071] The aerosol generation system comprises two main components: a cartridge 100 and an aerosol generation device 200. A connecting end 115 of the cartridge 100 is removably connected to a corresponding connecting end 205 of the aerosol generation device 200. The connecting end 115 of the cartridge 100 and the connecting end 205 of the aerosol generation device 200 each have electrical contacts or connections (not shown) arranged to cooperate to provide electrical connection between the cartridge 100 and the aerosol generation device 200. The aerosol generation device 200 contains a power source 210 in the form of a battery, which in this embodiment is a rechargeable lithium-ion battery, and a control circuit 220. The aerosol generation system is portable and has a size comparable to that of a conventional cigar or cigarette. A mouthpiece 125 is arranged at the end of the cartridge 100 opposite the connecting end 115.

[0072] The cartridge 100 comprises the heater assembly 10 of FIGS. 1 and 2 and a cartridge housing 105 including a liquid storage compartment having a first storage portion 130 and a second storage portion 135. A liquid aerosol-forming substrate is held in the liquid storage compartment. As shown in FIG. 4, the first storage portion 130 of the liquid storage compartment is connected to the second storage portion 135 of the liquid storage compartment by an annular component of the first storage portion 130. Thus, the liquid aerosol-forming substrate in the first storage portion 130 can pass through the second storage portion 135. The heater assembly 10 receives liquid from the second storage portion 135 of the liquid storage compartment. At least a portion of the ceramic transport material 14 of the heater assembly 10 extends into the second storage portion 135 of the liquid storage compartment and contacts the liquid aerosol-forming substrate therein.

[0073] Airflow passages 140, 145 extend from an air inlet 150 formed in the side of the cartridge housing 105 through the mesh 12 of the heater assembly 10, and from the heater assembly 10 through the cartridge 100 to a mouthpiece opening 110 formed in the cartridge housing 105 at the end of the cartridge 100 opposite the connecting end 115.

[0074] The components of the cartridge 100 are arranged so that the first storage portion 130 of the liquid storage compartment is between the heater assembly 10 and the mouthpiece opening 110, and the second storage portion 135 of the liquid storage compartment is positioned on the side of the heater assembly 10 opposite the mouthpiece opening 110. In other words, the heater assembly 10 is positioned between the first and second portions 130, 135 of the liquid storage compartment and receives liquid from the second storage portion 135. The first storage portion 130 of the liquid storage compartment is closer to the mouthpiece opening 110 than the second storage portion 135 of the liquid storage compartment. Airflow passages 140, 145 pass through the mesh 12 of the heater assembly 10 and extend between the first and second portions 130, 135 of the liquid storage compartment.

[0075] The aerosol generating system is configured to allow a user to inhale or withdraw the cartridge mouthpiece 125, drawing aerosol into their mouth through the mouthpiece opening 110. In operation, when a user inhales on the mouthpiece 125, air is drawn from the air inlet 150, through the airflow passages 140, 145, past the heater assembly 10, and into the mouthpiece opening 110. A control circuit 220 controls the supply of power from the power source 210 to the cartridge 100 when the system is activated, which in turn controls the amount and characteristics of the vapor produced by the heater assembly 10. The control circuit 220 may include an airflow sensor (not shown), and may supply power to the heater assembly 10 when the airflow sensor detects a user puff. This type of control arrangement is well established in aerosol generating systems such as inhalers and e-cigarettes. When a user draws on mouthpiece opening 110 of cartridge 100, heater assembly 10 is activated, generating a vapor that is entrained in the airflow passing through airflow passage 140. The vapor cools within the airflow in passage 145, forming an aerosol that is then drawn through mouthpiece opening 110 into the user's mouth.

[0076] In operation, the mouthpiece opening 110 is typically the highest point in the system. The construction of the cartridge 100, and in particular the placement of the heater assembly 10 between the first storage portion 130 and the second storage portion 135 of the liquid storage compartment, is advantageous because it ensures that gravity is utilized to deliver the liquid aerosol-forming substrate to the heater assembly 10 when the liquid storage compartment begins to empty, yet prevents oversupply of liquid to the heater assembly 10, which may lead to leakage of liquid into the airflow passage 140.

Claims

1. 1. A heating element for an aerosol generating system, the heating element comprising a mesh, the mesh comprising: a plurality of first filaments extending in a first direction, each of the first filaments including a first end and a second end; a plurality of second filaments extending in a second direction, the first direction being perpendicular to the second direction, each of the second filaments including a third end and a fourth end; a heating element, wherein the second end of the first filament is electrically connected to the third end of the second filament.

2. The heating element of claim 1 , further comprising a conductive portion extending between the second end of the first filament and the third end of the second filament.

3. 3. The heating element of claim 2, wherein the first filament comprises a first material having a first electrical conductivity, the second filament comprises a second material having a second electrical conductivity, and the conductive portion comprises a third material having a third electrical conductivity, the third electrical conductivity being greater than both the first electrical conductivity and the second electrical conductivity.

4. The heating element according to claim 2 or 3, wherein the conductive portion comprises at least one of silver, gold, and platinum.

5. The heating element of any one of claims 1 to 4, wherein each of the first filaments comprises stainless steel.

6. The heating element of any one of claims 1 to 5, wherein each of the second filaments comprises stainless steel.

7. The heating element according to any one of claims 1 to 6, wherein the mesh is a woven mesh.

8. 1. A heater assembly for an aerosol generating system, the heater assembly comprising: The heating element according to any one of claims 1 to 7. a first electrical contact connected to the first end of at least one of the first filaments; and a heater assembly comprising a second electrical contact connected to the fourth end of at least one of the second filaments.

9. 9. The heater assembly of claim 8, further comprising a base defining an opening therethrough, at least a portion of the heating element covering the opening, and wherein each of the first electrical contact and the second electrical contact is provided on the base.

10. 10. The heater assembly of claim 9, further comprising a conductive portion extending between the second end of the first filament and the third end of the second filament.

11. The heater assembly of claim 10 , wherein the conductive portion is provided on the substrate.

12. 12. The heater assembly according to any one of claims 8 to 11, further comprising a transport material for transporting a liquid aerosol-forming substrate to said heating element.

13. 1. A cartridge for an aerosol generating system, said cartridge comprising: A heater assembly according to any one of claims 8 to 12, and A cartridge comprising a liquid storage compartment for holding a liquid aerosol-forming substrate.

14. 1. An aerosol generating system comprising: A cartridge according to claim 13, and An aerosol generation system comprising an aerosol generator arranged to be removably coupled to the cartridge, the aerosol generator comprising a power source for supplying electrical power to the heating element.

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